I have been told and was of the understanding that the 1978/1979 front dana 60's were unique upon themselves and should be used whenever possible when doing 1978/1979 Bronco changeouts for minimal installation problems. Okay, I'll accept that if it's true. My current project involves swapping out a 1989 front Dana 50 for a 1989 front Dana 60 1989 circa in a 1989 F250.
My question has to do with the differences between the 1989 series Kingpin Front Dana 60 and the 1979 Front dana 60 as far as things like axles shafts (inner and outer), differentials, hubs, kingpins, and lockout go. I've spoken to a few different people and they say all those parts are interechangable vetween the 1979 and 1989 Front dana 60. I clearly remember some talk about the 1979 rotor hub assy being different than the rest of the 1980-1997 series but don't know what those differences are.
My last question deals with using a disc brake set-up foir my 1989 Dana 70U. Why is the brackett to mount the elderoado calipers on bent? What is the clearance issue on the rotors that everyone keeps talking about? I'd sort of like to know the answer before getting to that point so I can be prepared for it. Thanmks again for all your help.:confused:

The main differences are the pumpkin location and shaft lengths. My 85 60 is 2.5 inches closer to the left tire than a 78-9. Helps in certain areas and hurts in others. Calapers are different as in how they mount. Mine has two drive in retainers, the 78-9 has one with a reatining bolt. Inner C's are the same, outter knuckles are different (thicker around the upper bushing) but will interchange. Spindles, bearings are the same. Mine has 9/16's wheel studs already, the 78-9 has 1/2. My inner shafts dont neck down, most 78-9's do.

The 86 to 91 kingpin Ford 60's are 36.5" spring pad centers whereas the 78/79's are 32". Since the drivers side spring pad is incorporated with the differential, that means the differential is 2-1/4" more to the driver's side. Obviously, the inner axle shafts are different legnths between the different sets of years. I don't have much experience with the 86 up, but I believe the stubs are the same. The wheel hubs are the same. Therefore the older style hubs will work on the newer axles, but they stopped making that style in 79 for the 60, and 78 for the 44. The differentials and gears are the same. The king pins are by and large the same. The newer ones take a different top seal, and I'm pretty sure that's because the knuckles are different. I would think the older knuckles would work on the newer ones, and vice/versa, but not really sure why they changed. It may have to do with the fact that the newer set uses a drag-link to the opposite side like the 1/2 tons always have instead of the steering arm on the driver's side.

When swapping into leaf-spring 250's, the same group is the only real choice. If changing to a coil spring set up like the Bronco, the 78/78 is much easier because of the extra tube on the driver's side to weld on the wedges. To use an 86 to 91 you would have grind on the wedge and the spring perch to get enough room to install it. The other issue would be the 2-1/4" further outboard pinion. Probably good for the 80 up Bronco, but having never did this with 78/79 Bronco I can't say for sure how it would be.

I don't know anything about putting discs on a Dana 70.

Thanks for all your help. I didn't know how that 2 1/4" offset casing difference would be incorporated into the shaft lengths but common sense would tell me the inner axles on the 1989 circa Dana 60 would be 2 1/2" difference that the 1978/1979 series. So I was told correct, stay with the right years when doing the swaps or expect a bunch more problems!!!:homer:

Therefore the older style hubs will work on the newer axles, but they stopped making that style in 79 for the 60, and 78 for the 44. Lots of good info, but if your talking the lockouts I think you are, the 44 stopped in 77.


mgawat,
If i was you I'd go search on the SPicer Expert site. It will take a while to find the correct pdf for you, and a while longer to figure it out. However once you do you'll be set!

Just so you know the axle shaft lengths.
http://77cj.littlekeylime.com/Spicer/graph/Dana60_Front_Axle_shafts_Mr.N_.gif

Thank-you on behalf of a Recovering Catholic.:homer:

My experience has been that most of the 78's I've seen through the years are the "better" type. Most 78 axles were probably built in 77 like half of the trucks were. Its probably like the round light/rectangle light thing. I believe the reason they put them in that first half of the year and Rangers was to deplete their old stock of round headlights. They probably ran these hubs till they were gone also. Plus anyone replacing them probably would have drew from the old stock till they were gone also. I know, splitting hairs and off topic. Sorry. My fault.