I understand what you are saying. Overall, its probably too risky to try, and for all the trouble of modding the housing or complete axle assembly, I might as well leave the truck as a 2wd, or go with 3.54 gears. Overall, machining the D60 case sounds better, but since theres no 3.07 gears that are reverse cut for the front its a little pointless. Maybe I'll just convert my F150 to 4wd instead.

 

No reverse cut 3.07? I thought Dodge used 3.07 in their D61??

 

Yes, but my misunderstanding is that the gears are cut differently between the ford and the dodge applications (high pinion VS low pinion). The fords are designed specifically for front wheel drive (high pinion), the dodge is cut exactly the same as rear axle gears (low pinion), making them incompatible. I think there were changes in the 1994 and up dodge application, but have no idea if they would help my situation or not.

So the only real way to get the 3.07s in a high pinion housing is for a gear cutter to make an aftermarket set, but really, who is dumb enough to put 3.07s in a perfectly good high pinion dana 60? Most aftermarket gears are, well, "geared" toward off roading, so there is no market for reverse cut D60 3.07s gears. Oh well, maybe something else will come up eventually, 3.08 gears for the sterling were not very common when I got mine and others have since started offering them.

 

Oh yes.. see I wasn't thinking clearly! lol Forgot about the high pinion difference. I agree the D60 fronts are worth more intact and are for serious use. If you want to stay with 3.08s the D44 front might be acceptable. It would still give you 4x4. I would say just don't use the 4x4 while you have 10,000# in the back.

 

I toyed with the idea of using a TTB setup off a light F250, but for all the trouble of swapping to 4wd, I would like to get away from TTB if possible. I'm not sure what break systems are available on the older solid axle D44s, but its probably weaker than the dual piston setup I have now.

 

I agree I would like to get a monobeam. But I also think it would be an interesting experiment to feel what it is like to cruise down the freeway with my Diesel F250 under 2000RPM. It would be nice to experience that someday. When I combine the 3.55 w/5sp it will get them down about 350revs, but still be over 2200RPM most of the time. I suppose I can just keep dreaming about adding a GV unit in the future? If you go double overdrive it should take about 0.59 off the gear ratio. and get me to under 1800RPM on the freeway with 3.55s. With 3.08s could be cruising about 1500RPM down the freeway, it might be interesting to see if it increases MPG.. but might be a bit low? Your E4OD would be closer to 1250RPM at 80MPH.

I still think it would be nice if 3.08s were a viable option. If I am off-road and need 4 wheel I use low range which is more than low enough for me. I don't think I will ever be looking to put 40" tires on my F250. I prefer the stock 235/85R16 tires. I have a set of nice 16" Weld rock crusher wheels (same as stone crushers but with squared holes instead of round in the design) but they are much too wide for my stock E rated tires. D rated tires just don't cut it.

Sorry, I have gotten a bit off topic...

 

I'd love to get a Dana 60, but for what they cost, ugh.

Unless I can wrangle one cheap out of a junkyard, it may be quite awhile before I try getting one, because I'm not ready to pay $1000+ for just a front axle.

Also why would you be over 2200 RPM with a 5 speed and 3.55's?

I have 4.10's in my truck right now and it runs 2200 RPM at about 70 mph on the highway.

 

By calculation, at 70 MPH, my engine is turning 1610 RPM, the cluster shows 1550 when driving it at those speeds. 1200 RPM is underivable at those speeds due to higher engine loading from wind drag. The gearing I have is about the limit for how low you can go and still be able to drive it in the real world. For lower speeds like 50 MPH, I can "idle" along at 1000 or 1200, but I have to downshift as soon as there is the slightest hill.

If your wondering what its like to drive a truck that has "airplane dears" as catfish101 would say, well, even with a strait pipe the engine is impossible to hear once past 65 MPH, wind noise drowns it out completely. There is no longer a top speed either (speedo is pegged by 2000 PRM), I can cruise at 80 MPH and still get good MPGs (16-17). But for towing, again, its undrivable, so I pop it into 3rd, and lock the torque converter. 2200 RPM seems to be perfect for towing at 70 MPH.

 

ive seen one on an 84 f250 with a 300 six cyl it was a semi floating and it had the 8 lugs.... kinda seems week for what they were putting it under...

 

Yeah, the junk yards i called all didn't have any D60 fronts available but when they do have one they quoted me $1500 (at the cheapest place). I will periodically check the pickNpull but they seldom get 1-tons at all. and there are local shops who send their guys over to pull parts every week.. they go fast.

I was going by calculations using stock tire size... also at 70mph you would get run over around here. but at 70 with stock tires yes it should be about 2100 with 3.55 and about 2400 with 4.10 with a 5sp.

 

Yup, same here, although it depends on the time of day, and the day of the week, Weather conditions for some reason plays little role in the flow of traffic.

I often got very good MPGs when I used to make early morning runs. Start off at 5 A.M. and be home for lunch. The cold morning air made the engine happy, and traffic was usually more civilized (who rushes to get to work anyway?). But in winter, morning frost and black ice make that less appealing.

Slow lane flows at 75, (limit is 70) and the fast lane usually close to 80 unless there is congestion.

 

Kevin ,would you want to sell those 410 gears .will it fit a 89 f250 4x4 diesel 5 speed
thanks Eddie