I have seen the Sterling semi floating axle in an 86 F250, but it was a gasoline powered light duty.
300 six cylinder with a four speed.
Right now I can't remember if it had 6 or 8 lugs though.
It was in a 4x4, it got hung up on flat ground in wet grass.

 

Dave, Are the diff parts the same in the semi and the full floater?

 

Internally, the ring and pinions are the same between the SF and the FF. The carriers (differentials) are different to accomodate the C clip axles.

Jason

 

The rearend in the LD F250/ F150 7700lb and the Expedition is the Ford 9.75.

Jason

 

Remember, guys, from '80 intothe '90s there were both the F-250 and the F-250HD, the latter being the 8,600# GVW and the former around 6,600 GVW. The "regular" F-250 had the semi-float, either a Dana 60, 61, or the Sterling we are discussing. Both were rated for a 5,300# GAW (vs 6250# for the FF). The Sterling SF had the same center section as the FF (except that the side gears are machined for c-clips). As we all know, the light duty F-250 never came with a diesel.

I need to correct myself. I don't see the 3.08s listed under the semi-float, only the full-float.

As to 3.08s: Under the F-250HD/F-350 and E-250 columns. I see 3.08s available as an option in '85, '86 and '87 4x2, 7.5L gas and 6.9L diesel HD F-250 pickups and F-350 4x2s chassis cabs. I don't see 3.08s with any of the smaller gas V8s or the six. I'm not gonna check every book I have but the pattern seems to be that they were used only in combination with a big, torquey engines... which makes sense. How common they are is anyone's guess. Apparently not very, or Sponaugle for sure woulda heard of 'em!

As to semi-float D-60s and D-61s, they were very common and my Dana books are full of 'em. They are a very popular swap into Jeeps. The earliest ones came around '62 in some Chevy trucks, but they were a D60 center section with 30-spline shafts. I nicknamed them the "Wimpy-Sixty" because they were basically a D60 center with D44 tubes and shafts. A similar version was used in muscle cars (Mopars). Later, They were upgraded to 35 spline shafts and used by Ford, GM, Jeep and Dodge in vans and light trucks (heavy-half tons mainly, where they were a good fit). Ford and Jeep were the only ones that come to mind that used them in a 3/4-ton rated truck. A so-so application by most reports. Most people use 3/4-ton as 3/4-tons (which means as a one-ton) and wheel bearing failures were common for those folks. They were Ok as a towing axle if they didn't have to carry a big load. As somebody mentioned earlier, the D61 was just a version of the D60 with a housing set up for tall gears.

At the risk of being labeled a shameless self-promoter, if you guys would just get my book, most of this info would be available to you. Google "Differentials" with my name. You'll find it.

 

Jim, Good info. I wasn't familure with the semi 60's. I haven't ever owned one or ever worked a vehicle with one in it that I know of.

My 83 has a 61 in it and the bill of materials with the truck when it was new called the gears in it 307's. Same difference I guess.

 

Lots of good info there, Jim. I wish we had you on the forum more often.

Since you seem to be the leading authority on differentials, maybe you could answer a question about 3.08/3.07s for me. Is there any way to get a D61 front differential assembly off a dodge onto a D60 axle? Is there any way to get a D60/61 with 3.07s on the front end at all?

The idea of 3.08s come up often as a cheap way to make up for the lack of overdrive in these older trucks, but the front differential is a stumbling block.

 

The Dana 61 has a different casting that moves the pinion over 0.25"-0.437" (depending on the source) from a standard Dana 60. There are spacers available to use Dana 60 gears in a 61 housing, but I believe that you would need to machine the housing to use 61 gears. I'm not sure if there is enough material in the housing to cut it over a 1/4".

Jason

 

David85: Thanks for the nice words. I learn a lot here myself and when I have an opportunity to contribute something useful, I do my best to do so. Work gets in the way sometimes.

D60/61 Fronts: I'm looking at a '91 Dodge Data Book and it lists a Dana 60 front for diesels with 3.07 gears (probably a D61). My Dana axle book that year does not list such but does list Dana 61 front axles in some commercial Dodges of the '80 and early '90s. Look for a Cummins powered Dodge. '89-91 with what looks to be a D60 front. Many of those truck had 3.07 gears because of the extremely low RPM limit for the 1st Gen 6BT. They would have to be D61s. That would be the swap, I guess. Look for BOMs 610265-1 thru 4 ('87-88), 610333-1 thru 4 ('89), 610358-1 thru 4 ('91), 610431-1 ('92), 610406-1 thru 6. Those are listed for D-600 and D-700.

I seem to remember being told there were ways to stuff 3.07s into a Dana 60 housing too. I believe it was someone at Randy's Ring and Pinion who told me, but don't hold me to that. You could also put D60 knuckles onto a Dana 61 housing with relative ease for someone with welding skills.

 

To use the Dodge 3.07's, you would need to use the complete front axle which would put the diff on the wrong side. So you're back to retubing or installing the knuckle yokes onto a 61.
Good info Jim. Does your book cover Dana BOM numbers from the 60's- 2000's?

Jason

 

If its possible to reuse the D60 housing, that would be ideal, but I was thinking along the lines possibly of wielding a D61 housing on a D60 axle tubes (wielding is my day job). I am not sure what you mean by re-tubing though. My understanding is that the internal components between the D60 and 61 are interchangable (axles).

What about the 1994 and up dodges? the pumpkin is on the correct side for that year, but I'm not sure if they still used the D61. They also switched to coil springs, but that can be adapted.

 

RCrawler: If I had a book with every Dana BOM, it would be like the NYC phone book! There are some in there, but you'll just need to collect the Dana books. I have a bunch going back as far as 1950, with an irritating gap on many brands from '60-66.

David85: I forgot the diff on the wrong side. To a pro welder, though, shouldn't be a problem.

 

http://www2.dana.com/expert/wc.dll?cvsp~Depdf~5~AXL~

You might be able to find something at that link.

I think you need Adobe Acrobat Reader to look at the pages if I remember right.
You can also save the pages after you read them.

 

Thanks Dave. I've got a bit of information from that site. They don't cover much of the older stuff and anything past the mid 90's. Unless they've added a bunch in the last couple of months.

Jason

 

A little bit of knowledge can be a dangerous thing.. lets see if I am following this correctly.. In theory one could take a D61 frontend (or rear?, if buying new R&P) then find a D60 front from a Ford with a broken case and cut out the D61 pumpkin and cut the tubes off the D60 and it should all matchup.

I read that you can have the casting on a D60 machined down to accept the larger D61 pinion (I don't know what that entails or would cost to have done or if it leaves a weak spot in the case)