I did a search of the site, and can't comeup with any info on what is required to put 35 spline shafts into a dana 60 rear out of a 78-79 f240 4x4. Do I have to have the spindles bored out? does this create a strength probelem? what shops can do this in the SF bay area? do I really need the 35 spline shafts? it's going fullwidth in a 70 bronco with a SEFI 5.0 and 38.5 tires. thanks.

They had an article in Peterson's not too long ago. I'll try and grab it on my lunch and come back to tell you the steps!

You can have the spindles bored out to the same as a 35 spline. The outside diameter of the spindles should be the same...so there is not strength issue.

You can also have 14 bolt outers cut off and welded onto the 60 and then use 35 spline axles....

ask for 66cjdean on the pirate board he did mine though i would have had 14 bolt outer put on mine because there are more disc brake options for it and you dont loose any strengh mine is pretty thin at the end were the nuts go though it shouldnt be a prob, i worry alot ha ha :trooper: have fun

The stock axles will be fine for awhile. If you want 35spl, you can just grab a 61su, 70, or 10.25. Not a bad option if you are not going to cut it down. Also you can use 60 parts in a 61. But you will have to buy new gears if you do. Just get the series 4 carrier(locker whatever)and buy thick cut gears. The pinion in the 61 is offset an extra 1/2" or so.

I am doing this right now as well. Can anyone tell me if the Dana 70 spindle is the same dia on the OD as the Dana 60 spindle. My tubes are out, and I am about to bore the inside out, but I thought it looked a bit thin to bore the insides out.??

Thanks in advance.

Rod

The O.D. on the 60, 70, and 14 bolt are the same and you can even thread the nut from one onto the other because the jig I made works on all 3 and it has a 14 bolt spindle nut in it to align it all. So try the 4 wheeler web sit to see if they have a search and look for it because they did a wrightup a few months ago. The 60's that use the same inner and outer bearing are the better ones to do and boreing them out to 1.600 is no problem as far as beef goes. I can bore out the spindles but you would have to cut them off first cuz I do them in the lathe.

I was out at PNP the other day doing a little research and about half of the 60's I pulled axles out of had 30 spline shafts with a spindle that would fit a 35 spline. Pulled a 35 spline shaft out of a 70 to make sure. I thought all the ff60's had the small spindles but I guess you can find them that don't need to be bored.

cause I already got a 35 spline 60 stock!!

hehehe no problem here!!!!!!

good braging rights to - cause people are alway breaking their c clip 35's so I just say hmmmm I got a c-clip and never break it!!

Originally posted by CRAWLR
I was out at PNP the other day doing a little research and about half of the 60's I pulled axles out of had 30 spline shafts with a spindle that would fit a 35 spline. Pulled a 35 spline shaft out of a 70 to make sure. I thought all the ff60's had the small spindles but I guess you can find them that don't need to be bored.

Almost all HD60s have the larger bore spindles and 30 spline shafts. So do the D61s so make sure you are getting the correct axle.

Here is a pic of a large-bore spindle on my 60HD axle housing:

http://darkwing.uoregon.edu/~jrice/cruiser/D60HD/D60HD-6.jpg

Medusa

That is a top shot, but your hub looks different to mine.

Is that hub easy to pull off? Would you be able to measure the O.D. where the nut screws on and the OD where the outer bearing sits on the spindle.

Thanks in advance if you can.

Regards

Rod

Medusa, great pic :) What year D60 is that? Mine ('73) uses bolts not studs for the axle flange. Or did you convert to studs?
BTW cool calipers...I use the same model Mititoy and have found it to be the most reliable and smooth caliper to use for my work (Machinist).

Thanks,
Eric

Most of the HD60s use studs instead of bolts like D60s and D70s. Or maybe it is just a Dodge thing :confused:

What vehicle did you get your 73 D60 from?

The housing pictured came out of a '71 Dodge 3/4 ton. The axle flange studs are original.

Rocket, I will try to get the measurements you requested next week.

Thanks Medusa I look forward to seeing them.

Rod

btt

So what is the deal here? I have a Jeep J20 rear Dana 60, that should have 30 spline shafts. Is it as simple as getting some 35 spline 14 bolt of Dana 70 shafts and having them cut and resplined to fit my narrowed housing?

I already have a 35 spline Dana 60 carrier that is welded and is coming out of my front axle, so it would be nice to re-use it in the rear....

Any thoughts?

This almost works DRM. You need to make sure your spindles have a big ID to slip the 1.5" shaft through. Most D60FF rear ends spindles do not have an ID bigger than 1.5" so you must bore them out so the shaft will fit. Shaft selection depends on how much you are going to cut them down. Most of the D70 shafts that I have seen begin to taper down after the splines all the way to the axle flange. This may not be enough to worry about for spline contact. I don't know if 14 bolt shafts taper at all.