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1978 F250 Dana 60 on to 1985 Burb

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Ned Kelly

1/2 ton status
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So what does it take to install a 1978 F250 Dana 60 front onto a square 4x4?

We have a donor with vehicle 4x4 6.0/6L80e and transfer case (not sure which one as I don't know these newer IFS trucks) drivers drop....and the Ford D60 diff would be on the correct side for the tc.

Any IFS GM drivers drop transfer cases to stay away from?..or they all good?
 
Take it out of the Ford. Put it in the chevrolet. Pretty easy.
Get gm steering arm if you're keeping stock steering. Boom.
 
It's not exactly the same. The Ford is a hair narrower spacing but I managed mine just fine.
 
The Ford uses all u bolts too. But they were originally the upside down style with the threads pointing down. The big u bolt that goes closest to the differential where the GM60 has studs you will need to ground a groove into the cast iron for the u bolt to sit in or it looks all wonky like mine.

Watch your oil filter and your exhaust will need changed.
 
454Sub said:
It's not exactly the same. The Ford is a hair narrower spacing but I managed mine just fine.
Click to expand...

No issues with spring eye bushing wearing out faster? I think I recall Dodge D60 were 1/2" narrower or so, but would still bolt in, and guys were stating the spring eye bushings would wear out faster due to the misalignment. Not sure if this is the case with the Ford D60.

Good point on the Ubolt issue 454Sub. Any pics of your setup?
I'll check on the oil filter location, hadn't thought of that yet. Yeah, it will get a whole new exhuast with the 6.0/4l80e swap, but a good point when keeping an original motor/trans.
 
ORD or someone has some offset bushings that may help the slight misalignment...

As stated, the driver's side diff swap may interfere with the oil filter...
 
All good info, and links. Thanks.

With the Ford hi-pinion D60 front....will I be ok running only 2 1/2" of lift (on 1985 Burb chassis) ?
Wasn't planning on much more, and maximum 4" lift.
 
Couple other minor things too, you'll need to weld on some new shock tabs and come up with a way of mounting the Chevy sway bar (if you're keeping it) and the steering stabilizer as the Ford mounts are all just a little different. @obijuank5 was spot on with needing a GM steering arm which shouldn't be hard to find off someone converting to high steer and the wheel studs are also different so you'll want to swap them out too or you'll be running mismatched studs and lug nuts. I have a GM steering arm that another member hooked me up with a while back that I'm not going to need now that I'm going with Sky arms. If you want to cover the shipping you can have it.

I have a 79 Ford D60 sitting in my garage waiting to go under my K5 and picked up a simple swap kit from Ruff Stuff that came with shock mounts, u-bolts, u-bolt plates, and a spare spring perch in case yours has seen better days. Just keep in mind you'll have to grind a little off the diff housing to use that style u-bolt. Here's a pic from ORD's site that shows what we're talking about:
Ford D60 U-Bolt Notch.jpg
 
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