I have been searching for some replacement parts for my DANA 61 and I called our local tranny/diff gear guru for the parts. He has told me that upon running the numbers that I gave him by his suppliers we've stumped them. They are telling him that I have a DANA 61 with DANA 60 parts? But he is telling me its impossible, they don't interchange..... there seems to be major confusion going on. Can anyone help?

What's the major differences between a 60 and a 61? I have opportunities to switch, will all of the components off my axle swap to a 60? (eg: brakes springs etc..)

thanks Chris

Here are the numbers I've got:

axle code 22j

orig data tag 3 07 D8TA AFA
603899-1

2nd tag covering orig: 3 73 D6TA EVB
603715-5

Cast on web of axle left of diff cover: C38390
Stamped into bearing cap: C30257
stamped into ring gear: 11 17 76 34508 A3D78X41 11
Cast into web above right pinion side of case: 61-2
stamped into tube left of spring u bolts left side: 278
stamped into tube right of spring U bolts right side: 258
stamped into axle tube left of diff; 8 2 8c1 603899 1

I can't remove the pinion at this time to retrieve the numbers off of it..

thnx

I found a DANA 60 axle code 24J off a 77 F250 4wd, should I just get it and be done with it? Its been sitting at the pnp for 3yrs..I'm hesitant because I don't want a different dog same fleas...

 

OK some time ago I ran into this same question myself cause i had a dana 61 in a truck I bought. Internally the 60/61 are identical for part exchanges. The difference is in the casting of the housing the 61 is cast a little thicker and with stronger webbing to accomodate for the higher gear ratios and their strain that were available back then, im not sure of the ratio # they transitioned between. Anyway I went from a stock 2:47 open diff which could run 140 mph to a 4:10 locker using ala new parts for a dana 60 and replaced everything internally and not one problem.

 

With mileage and emissions concerns rising, at some point Dodge and / or Ford decided they wanted to be able to offer gears higher than the current highest ratio of 3.54 available in the D60. However, because of the design of the D60 the pinion head could not be made big enough to achieve a higher ratio. Hence, the birth of the Dana 61, which has a different casting that moves the pinion over 0.25"-0.437" (conflicting reports) - this allowed for a 3.07 axle ratio. The Dana 61 also uses 3.5" axle tubes. Other than that, it is very similar to the Dana 60. The Dana 61 was common in Dodge front ends and Ford truck/van rears.

The difficulty with the Dana 61 is very limited gear and locker choices. However, you can use a combination of ring gear spacer and thick gear set to allow the use of differentials and gear sets intended for the Dana 60.
To run a 4.88 you will have to go with series 3 carrier, series 1 being 4.10 and down, series 2 being 4.56 and up, then the series 3. PLUS a .160" spacer. That's the problem, nobody makes a full case locker for a 61, but it could be doable with a thick ring gearset AND a spacer.


Reider racing< Randy's R&P, and other sources make ring gear spacers for the Dana 61 .

http://www.reiderracing.com/ringspacer.htm

 

You will pay dearly for that precious spacer, I have read that folks claim it needs to be different thicknesses. IMO, I would swap out the entire unit for another good, used axle. You can find them used for anywhere from free, to $400 depending on where you looked and your luck that day. When you go shopping, things to look for are the color of the oil, any metal shavings at the bottom of the housing, condition of the brakes, wheel bearings, and most importantly, the gear pattern. I like to turn the yoke a few degrees to see how much play is between the ring and pinion. A very small amount is OK(and is supposed to be there) but excessive play means worn or improperly set up gears.

 

Thanks for your help....

i contacted reider racing amd spoke to Jeff, he was very helpfull and knowledgeable . He ran all the numbers for me.. and judging simply be the lack of spacer, i am not running a DANA 60 in a 61 axle... he has everything I need (carrier 80$, spiders 56$ and a master rebuild kit for 150$.) great prices as cheap or cheaper than a used axle, without the headaches...I will be rolling soon!

thanks again C