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Discussion Starter #1
Now that Artec has their TJ 1 Ton SD front 60 swap front kit available, Let's see what you got and your thoughts.

HERE- TJ 1 Ton Superduty Front Axle Swap Beta

I know that there are some beta testers out there. What do you think?

Which do you prefer? Why?
Choices are for '99-'04 or '05+,
Daystar, Currie JJ or adjustable truss upper link bracket.

Show your axle build here.
 

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Discussion Starter #2 (Edited)
I'll start.

I ordered the Artec TJ/XJ 1 Ton SD 60 swap kit, pre-order -15% off and Black Friday -15% off. '99-'04 and Currie JJ. Waiting on the ship date.

It is going into my DD/wheeling '98 XJ with Rock Krawler 3 link. Will have 37" MTRs on ProComp 1069 17"x9 4.75"BS wheels. Notch Custom flares, about 5" lift and JKS ACOS Pro bumpstops and Bilstein shocks. Maybe 1" pushed forward with the long arms. Probably a Auburn ECTED LSD/electric locker.

Looking at machining the knuckle tops for high steer arms. Want to use off-set TREs on the stock arm OTK tie bar and passenger high steer arm for the steering drag link arm and the driver high steer arm for the hydro assist ram to a steel cover.

Unfortunately I bought a SD50 thinking it was a SD60. My bad but I think that it will be OK with the 37" tires. In my area, SD60s are carrying a huge premium price.

The SD50/60s have 1350 yokes and will need new driveshafts so looking to change the yokes on the 231 transfer case to 1350s also. Or use a 1310/1350 conversion yoke or just stay 1310 at the transfer case.

Also got the 10.25 for the rear and will use Ruffstuff U bolt eliminator spring perches. So will also need a 1350 rear driveshaft.
 

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Discussion Starter #3
Learned something today about the D50s.
Excursion V10 and 7.3L diesel came with 3.73s and the 5.4L V8 came with 4.30s.
 

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Sounds like a decent plan. Right now I am retro-fitting their (Artec) 99-04 SD JK system for a XJ on a 05 SD60. Its not bad, just need to refit the truss for the narrower spring width and larger axle tube of the later Dana 60 model. Depending on where you are, I have an extra 06 SD Dana 60 complete that I would sell you cheap, just to get it out of storage.

That D50 will most likely hold up to 37's, but thats alot of axle housing for 30 splined shafts.


I went with the 05 D60 because of 35 splined shafts factory, huge brakes and simpler unit bearing than the early gens (99-04), no shims. I already sent my knuckles out to 4wheelsupply for their highsteer retro fit, so planning on tru-highsteer to get out of my ruffstuff diff cover's way. Plus I found 2 fronts and a matching rear for $500 complete. Granted the rotors and pads are shot and they need to be sand blasted and such........but for the price, I could pass the deal up.
 

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Discussion Starter #5
You're about 3.5 hours north of me. I'm in Trenton/Phili area. Tempting on that '05 D60. We just drove 1 hour to get another D50/10.25.
 

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You're about 3.5 hours north of me. I'm in Trenton/Phili area. Tempting on that '05 D60. We just drove 1 hour to get another D50/10.25.

Could meet you half way if you want. At least I have an extra for parts if not, LOL!!

The other thing about the +05's they are wider.....WMS - WMS is 71.5" compared to ~69" of the 99-04.
 

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You're about 3.5 hours north of me. I'm in Trenton/Phili area. Tempting on that '05 D60. We just drove 1 hour to get another D50/10.25.

Could meet you half way if you want. At least I have an extra for parts if not, LOL!!

The other thing about the +05's they are wider.....WMS - WMS is 71.5" compared to ~69" of the 99-04. Plus have a larger Axle tube OD, so that Artec truss/system, won't quite drop on.......you'll have to do some cutting and grinding.

Just put it all there.
 

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Discussion Starter #8
It's all these little details.

Didn't know that the WMS was different between the '99-'04 and '05+.
We are trying to keep the tires as close as possible under the Notch flares on the XJ and we figure that they will still stick out about 1-1.5" on each side which we can live with. The '05 with 2.5"+ more width, 1.25" on each side, We are trying to avoid the obvious 1 ton tire outside the fender stance.

And the '05+ is coil spring and a huge amount of cutting to get the spring and control arm mounts off.

And you say the unit bearings are different? Bigger? are they interchangable?

I still might be interested in the SD60 for a different project. PM me a good price. Or I'll save it for a rainy day when our Ranger with a SD50 breaks with the 42s, ha.
 

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Discussion Starter #9 (Edited)
Took a few measurements of the center of spring perches-

XJ/TJ- D30- 36", WMS=60.5", Rear 8.25- 43.75"
SD '99-'04- D50/60- 38", WMS=69.5", Rear 10.25- 44.5", WMS=68.5"

That makes sense why Artec says that their front spring perches are 1" further outboard than the stock TJ/XJ.

Rear is damn near direct bolt in. I'll try and measure more accurately later rather than just me and a tape measure.
 

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I'm in the beta for the 05 kit for my 97 TJ. I chose the 2005/Sterling axles because I got a great deal. I knew tons were in my future, especially after blowing up the D30 AGAIN! This swap kit makes for a cheaper entry into the expensive nickel and dime world of one tons.

I chose the stock style kit with UCA mounts with JJ, but converting the LCA's to long arms for better fitment and function for now. I also ordered Weaver knuckles, for high-steer full hydro PSC with Artec Ram mount.
http://www.pirate4x4.com/forum/axles-tires-wheels/1761249-2005-up-ford-dana-60-hi-steer-kits.html

Still have a lot to figure out, but its getting closer to completion!

This is the front as purchased~




Trimming the housing was not as bad as I first thought, but still quit the job!






The finished product~
 

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Discussion Starter #13 (Edited)
I agree, and I am going to use either Weaver/FordTechGuru or FourWheelSupply.net machined knuckles and high steer arms. I am using Procomp 1069 wheels 17x9 with 4.75"BS and 37" MTRs, and I have to see if the high steer arms will clear the rims. I might need different 'curved in' high steer arms for rim clearance.

Here in PA full hydro is not 'street legal'. There must be a mechanical connection to the steering. I want to use Ruffstuff offset TRE tie bar on the stock knuckle arms OTK for more ground clearance and the offset TREs for needed diff cover clearance at full lock.
Then the passenger side high steer arm will connect the steering drag link with TRE either OTK or more likely UTK to give more room up high.
Then the driver side high steer arm will go to the hydro assist ram.
And still have to have room for the track bar.

Or at least that is the current plan.
 

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Discussion Starter #17
RANDOM FACTS

TY/XJ D30-
-tube 2.5"
-WMS 60.5"
-center of spring perches-- front-36" rear 8.28-43.75"

'99-'04 D50/60
-Excursion D50 '00-'04
-tube 3.5"
-F250/350 '99-'02 D50 '229' 9" ring gear coarse threads 14x2
-F250/350 '02-'04 D60 '248' 9.75" ring gear fine threads 14x1.5
-WMS 69"
-center of spring perches-- front-38" rear 10.25/10.5-44.5"
-30 spline outer shaft stubs 9.39" long (need to bore and mill center ID for 35 spline conversion)
-C 9.75" top to bottom, all F250/350 have the same C
-Caliper lug mount spacing 10.5"
-Unit Bearing 4" square bolt mounting holes
-'03-'04 V10 4.30 gears and 10" ring gear

'05-'08 D60
-tube 3.75"
-WMS 71.5"
-ring gear '256' 10"
-F250/350 1480 U joint, big enough for 1550 U joint conversion
-F450/550 and F350 DRW-- SUPER 60 1550 U joint
-all 35 spline, shorter stube, Fine threads 14x1.5
-bigger knuckle than '99-'04
-bigger unit bearing than '99-'04, sealed, 4.5" square bolt mounting holes
-C 11" top to bottom
-uses different dry slugs- smaller than '99-'04

'05-'08 SUPER 60
-C 12" top to bottom
-F450/550, F350 DRW, ?some King Ranch
-bigger Ball Joints, bigger Brakes 14" rotors
-1550 U joint
-Larger knuckles '05-'08 D60
-same size unit bearing as all '05-'08
-40 spline outer stubs

'09+ D60
-3.75" tube
-WMS 72"

Please correct or make additions.
 

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I am a beta tester for Artec and couldn't be happier. I've put up a thread in non hardcore on my swap so far but I was able to get some 09 axles cheap. Going under my 00 tj with 40" nitto trailgrapplers. Artec has been awesome to work with and the craftsmanship on the truss is impeccable! I'm loving what I have so far.





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