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Shorter...How much shorter? My 04 30 spline stubs are 9.39" long, and I thought that was short.
This is what I mean by SHORT. OEM '05+ SD D60 stub.



Though, once the OEM lockouts are removed there is room to use longer, custom stubs for ease of machining and full hub spline engagement. Here are some custom Yukon 4340 stubs I had made.



And finally, just for the sake of getting some pics in this thread, here are some of my high steer set up and hubs (redrilled 8x6.5)





 

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If you want high steer for the 05+ super duty axles, Toby Lavender from XXX traction has figured it out. Give him a call.
 

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I put a 06 60 in my 98 Durango, I used the factory ford steering box, I had to shorten the linkage a inch or so. I made spring buckets and use the factory spring mounts. I also used the stock ford radius arms. I install 4:88 with a lock rite. It is by far the beefest 60 I have ever pulled apart.
 

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What is everybody using for spring plates and u bolts when running leaf springs with these axles? Ive got an 02 60 and I need a set just not sure what I need.
 

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This is what I mean by SHORT. OEM '05+ SD D60 stub.

Though, once the OEM lockouts are removed there is room to use longer, custom stubs for ease of machining and full hub spline engagement. Here are some custom Yukon 4340 stubs I had made.
What did the chromo axles cost?
 

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hi-steer ninja
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yes, the 05'-up knuckles use the same unit pattern (all), 99-04 is smaller..
not 100% on the ball joints but i will check..
basically the inner c is taller on the 05'-up dana 60 to accomidate the 1550 u-joint, but, not all 2005'-up axles came with the bigger u-joints, they were all 35 spline but the "super 60" had the 1550 joints. not all f-450 10 lug axles had the bigger shafts, the unit i picked up was a f-450 with a 3.73 gear (non-10") and std. axle shafts but had the 10 lug adaptors. the way the dana chart reads, any axle with 3.54, 3.73 or 4.10 gears had the small shafts and standard 9.75" gear, any axle with 4.30, 4.88 or 5.38 gears had 1550 shafts and the 10" "super" gear. you can swap the axles or gears from either one either way...
 

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So if you got a 05+ super 60 with the 1550 joints, could you use the 8 lug unit bearings? Or better question, who makes aftermarket shafts with a 1550 joint. Sice the 10" gear will fit in any 05+ housing (that is correct right?) and the came with 5.38's factory, it should be easy to upgrade to those bigger gears. I assume the lockers are the same, so an arb would work. Are the knuckles different on a super 60, or will all 05+ super duty housings accept shafts with 1550 joints?
 

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http://www.4wheeloffroad.com/techarticles/drivetrain/131_0906_dana_super_60_front_axle/index.html

guess I should have read this... article says end forgings are bigger, and I assume that means knuckles are bigger. Still wondering if 1550 shafts will fit in 05+ non "super 60" housings... WMS on super 60 is 84+ inches. WMS on stock SD 60 is 72+. Swapping 8 lug unit bearings and brakes onto the "super 60" gets the WMS to 74. Add an inch of back spacing to your rims and you are back to 72 so that is no to big a deal....
 

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**I think** that the housing itself is bigger/wider on the 450/550 "super60".

Also If the ball joints are the same and all 05'+ came with the same balljoint spacing. Are \/these\/ the only differences between the 05'+ axles;

-Super60 has 10" ring gear (on 4.30 and lower gears axles)
-Super60 has 1550 joints (on 4.30 and lower gears axles)

Other than /\this/\,the adapter/spacers for the 10lug and width of housings what else different on the 05'+ axles?

Outer knuckles are different right? Bigger brakes and stuff.
 

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hi-steer ninja
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x-rated see my previous post.. the unit bearing and the knuckle are the same on all 05-up 60's... (there is a slight casting difference on 08-up knucks) edit: 05-08, 09-up different knuckle, f450/550 bigger knuckle..



k-runner, the coil spring axle is wider than the leaf spring 99-04 axle, the difference is bigger axle tubes, bigger c's, bigger unit bearings (about 30%) , bigger brake rotors on all 05-up axles, the "super" axles got the 1550 axles and the 10" gears... dana lists the "super axles" as 05-up, but, i am calling the 1550 stuff with the 4.30, 4.88 and 5.38 gears the "super" axle since they have all the goodies... i don't believe i have seen a broken 1550 axle yet from a super 60. yet.
 

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yes, the 05'-up knuckles use the same unit pattern (all), 99-04 is smaller..
not 100% on the ball joints but i will check..
basically the inner c is taller on the 05'-up dana 60 to accomidate the 1550 u-joint, but, not all 2005'-up axles came with the bigger u-joints, they were all 35 spline but the "super 60" had the 1550 joints. not all f-450 10 lug axles had the bigger shafts, the unit i picked up was a f-450 with a 3.73 gear (non-10") and std. axle shafts but had the 10 lug adaptors. the way the dana chart reads, any axle with 3.54, 3.73 or 4.10 gears had the small shafts and standard 9.75" gear, any axle with 4.30, 4.88 or 5.38 gears had 1550 shafts and the 10" "super" gear. you can swap the axles or gears from either one either way...
Do you know what part of the Super 60 is longer? Driver side tube, passenger side tube, or both?
 

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Fawk this whole "Super 60" name thing...
It's simply a nickname that was given to the "450-550" axle by Ford Motorsports... And now-a-days most people call the "250-350" axle a "Super 60" too, so it's just simply confusing!
Some "450-550" axles don't have 1550 U-Joints so....
Some "450-550" axles don't have a 10" ring gear so...
Some "250-350" axles did have a 10" Ring Gear so....

The name "Super 60" doesn't clearly define anything anymore!

Generalizing them all as a "Super 60" is OK-ish I guess but for clear discussion purpouses calling them "250-350" and "450-550" is a lot more accurate IMO.

Both sides on the "450-550" are wider than "250-350" AFAIK.
I'm about 90% sure the Radius Arm Bushings are placed the same width apart on both axles, but on the "450-550" both tubes are longer from the Bushings out. I just bought a 550 axle and it should be here within a couple weeks, then I'll be able to measure and be sure.
450-550 Inner Shafts can't be cut down and re-splined to fit in a 250-350 housing cuz even though they are long enough there's a neck down just past the inner seal. You're stuck getting custom shafts if the stockers aren't strong enough for you.
It wont be long till there are plenty of aftermarket shafts available for the 250-350 housings with 1550 U-Joints.
1550 U-Joints will fit in a 05+ 250-350.
 

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It wont be long till there are plenty of aftermarket shafts available for the 250-350 housings with 1550 U-Joints.
1550 U-Joints will fit in a 05+ 250-350.
awesome. Should be a good step up from the "normal" D60 sized stuff without the need for "full custom" or "hybrid" axles with rocwell outers.

Especially if you run 40 spline D60 diff with 40 spline 1550 axles (when they are available).

of course it may take several years for the aftermarket to have the demand for such a beast.
 
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