I've read (on this board) that the outer diameter of the rear D60 FF spindles are all the same, and that only the inner diameter differs from 30-spline to 35-spline models.

I was given contradictory info today (by Dutchman Motorsports) that there are two sizes for the outer diameter of the spindles: 1.75" and 2". Mine is a 30-spline 60 with 1.75" OD spindle; the ID is close to 1.45" now.

I want to bore out the spindles to ~1.550" to fit 35-spline shafts, but I'm concerned that the spindle wall will not be thick enough (it would be about .1" thick after boring).

For those who've bored out the spindles; what was the resulting wall thickness? What is the minimum ID to fit 35 spline shafts?

anybody?

I'd like to know how many people have done this with an adjustable hand reamer and if its worth the time to save some money.

Im sorry but dutchman is wrong, 30 and 35 spline 60s use the same outer bearings.

So are the dana 60 and dana 70 bearings the same too?

http://www.pirate4x4.com/tech/billavista/D70/D70.htm

Bottom of page

My Ford D60 front, Chevy Dana 60 front, 14 bolt rear and D70 rear all use the same inner and outer wheel bearings, cup and cone.

Seals are different

Here is a post with some info.. I bored my D60's out and so far........... Its' ok... Unfortunately I did not keep any of the specs.

http://www.pirate4x4.com/forum/showthread.php?s=&threadid=102957 (D60 post)

Ricky...seeya...

Ricky, did you bore them yourself?

Originally posted by Bushwhacker
Ricky, did you bore them yourself?

No, I took the axle (stripped down) to a machine shop and they did it.

Here is one of my replies in the older topic.

snip..

I did my D60 about a month ago. I took the axle to a machine shop and had it bored out there. They charged $90 to do the job. A d60 16 spline axle probably wont work. I have one of those and looked at the spindle and they slightly neck down at the outer bearing. This WON'T do !!!!!!!
I'll have to check the inside diameter, but it looks liks very little metal was removed. I got a set of Dutchman axles,

another snip>

As long as the shop puts the axle in the lathe properly there should be no way for this to come out crooked. Our local shop used a 1 5/8 drill bit ( 1.625") it took them 1 day to fit it into their schedule. The Dutchman shafts are slightly necked down 10" from the flange and there is plenty of room for this to keep from having problems.

Ricky...seeya...

I had mine bored to 1.625 by a local machine shop. The only place it looked suspect was at the end where the keyway is it looked very thin. In the end, I got moser 35 spline shafts. The shafts have a curved portion where it meets the flange that the original axles don't have. Moser tells you that you might have to grind down the tip of the spindle to allow room for this curve. After I ground down the spindle enough to stop the binding, (which was quite a bit) it didn't have that super thin portion anymore. Lots of people have done this with no problems. Go for it. If you go with 1.55" I think you are going to have problems, I would not bore it to less than 1.6".