I have a '77 F250 2wd Camper Special with a Dana 61 rear axle with 3.07 open gears. I want to swap it with a '78 2wd Dana 60 with 3.54 open gears...swapping only the housing w/gears, and reinstalling the Dana 61 brake backing plates, brake drums and axles that are in the truck now, onto the 60 housing. Will the Dana 61 axle shafts work in the 60? Are the wheel bearings and seals the same from Dana 61 to Dana 60?

I guess what I'm asking is; what are differences between the Dana 61 and Dana 60, and what swaps and what doesn't?

Thanks all.

 

Ok, this one is tricky. The 61 is rumored to use Dana 70 spindles. I have never been able to get my hands on one.....so I can't confirm. If it DOES use Dana 70 spindles.....then most things won't interchange. If you don't know how to spot the difference between a 60 and 70 hub, you're gonna have to pull an axle shaft. Measure the inside diameter of the spindle on the 61. If it's greater than 1.5 inches, it has a 70 spindle. If it's less than 1.5, it's a 60. It sounds like the donor 60 axle is in poor shape. I hope you're getting it for really cheap. Because you could just get 3.54 gears for your 61.........

 

Hilbilly...its a rear axle...no spindles!

The 60 is in good shape...I've had it hangin' around the shop from another build in the past....just missing the brakes and axles...perfect for my swap if the 61 parts will work.

 

.....rear axles have spindles too. They just aren't removable.

This is a Dana 70 rear spindle....a very BAD Dana 70 spindle.

Notice how the inner bearing is larger than the outer bearing? A Dana 60 spindle uses the smaller size outer bearing on the inside too.

 

OK...you got me there. I was thinking you were talking front (steering) spindles. Sorry.

I have heard from other sources that the only different thing is the center casting ,for more pinion clearance, for running higher final drive gears (3.07:1 and 3.31:1), but I want to confirm this before I start tearing into my current setup.

 

Measure the tubes. The 61 supposedly has thicker tubes. They are 3.5 inches, vs 3.125 on the 60. If the tubes really are thicker.....then you really need to check the spindle. If the 61 has 3.125 tubes, then it's a safe bet everything will interchange.

 

Good point Hillbilly. I'll check that out. Thanks

 

There is much debate about the 61. As you may know, the 60 will NOT accept 35 spline axle shafts. People claim the 61 will accept the larger 35 spline shafts......which means it must use a Dana 70 spindle. If that's the case....then your brakes are not gonna interchange. The Dana 70 hubs have a larger pilot diameter for the brake drums......among other things.

How about just putting the 60 gears in the 61 housing? There is a ring gear spacer available that allows such a thing.

 

OK, I just measured the outside diameter of the axle tubes. They are both 3.145 in.

Re: getting the 60 gears setup in the 61 housing....I'm trying to avoid the $300-$400 setup charge for doing that....and the cost for the spacer.

 

Well...now would be a good time to learn to do the gears yourself....lol. Glad to hear the tubes are the same. Everything will probably interchange. I was trying to get some solid info on the 61. I wanted 35 spline shafts for my rear axle, and apparently SOME 61's have the big tubes and will accept the big shafts. However, I couldn't find out exactly WHICH ones did. And, I couldn't get my hands on one to check for myself.....so I just gave up. Decided to move on to bigger and better things......picked up a Dana 70 HD yesterday

 

I've got a buddy who has a 61 that we are gonna swap out for a 60. I can't tell you if the 61 brake parts will bolt up to the 60, but I can tell you that the drums and pads are different. I'll see if I can get him to chime in on his experience with the oddball 61 (which he dislikes due to parts availability by the way)...

 

I found some information late last night. The brakes are related to the tube diameter. Some 61's and some late model 60's have 3.5 inch tubes. They are only found in E-series vans. The Dana axles were phased out of the trucks in the early 80's. But I finally saw some pictures and they DO use Dana 70 spindles. This is what allows them to fit the 35 spline shafts. But, they also use Dana 70 style brakes. But, since your 61 has the small tubes, it uses the Dana 60 spindles. So, everything should fit.

 

I talked to PoweTrax in Orange CO., and they had some notes saying that hey can re-gear a 61' and add a traction device if needed. But to my understanding, only 4:10's can be used.
**By the way AerostarDad, what width are your leaf springs? 2.5" or 3"?
I'm sawpping in a 60 for ease of parts. I had a hell-of-a-time finding brake parts for this thing. I finaly got new drums for them at a salvage yard. The owner said he ordered them for a guy who never showed, back in 84'. I got them in 2002. They sat on his shelf that long because NO ONE ever asked for these types.

 

Just to clarify - Do you really mean Orange CO. or did you meant Orange County CA Jason?

 

OK, here is my 2 cents worth. I blew up a Dana 60 in my 77 F-250 4x4. I was leaving the next day for a road trip and had a Dana 61 sitting there. I swapped the backing plates, and drums from the Dana 60 to the Dana 61. I think I used the Dana 60 axles also. Bolt in. Wham bam. Didn't want to have to bleed brakes ect. Once I found another Dana 60 housing, swapped everything back.

BTW, 3.07 gears + 39" tall Mickey Thompsons = horrible gas milage. 70mph was 1500 rpm. LOL

Steve S.
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