Rebuilding Dana 60 (question on parts)

[1-ton]

I am starting to purchase all the parts to rebuild the Dana-60 on my Crew Cab. It is only used for light wheeling. I am buying a complete ring & pinion (5.13:1) and install package (with Timken bearings) for both the Dana-60 and the 14-Bolt FF in the rear ($600.00 total/free shipping). I am also buying a new open carrier (4.56 up), Spartan Locker, inner 4340 axles, and outer 4340 axle stubs for my Dana-60.

My question is about the outer stub axles. I am torn about going with 35-spline outer stub axles, or staying with stock 30-spline stub axles. Since I only do light wheeling with this truck I am not sure if the 35-spline stub axles are necessary. There is also the added cost of a set of locking hubs that can stand up to 35-spline axles. Any opinions on this?

 

[K5chevyLQ4]

Why are you replacing axles shafts? Seems like factory axles would be plenty strong. Have you ever broke an axle on this truck?

 

[Bent77]

If you’re not a lead foot or a rock slammer, the stocks and 30s should be fine

I have a axle builder buddy that swears 65% of axle break while backing with the front axle locked. So don’t do that

I beat my 60 like a baby seal and didn’t break the 30s. Seen other snap them on what seemed like a bunny slope. YMMV

 

[1-ton]

Why are you replacing axles shafts? Seems like factory axles would be plenty strong. Have you ever broke an axle on this truck?

If you’re not a lead foot or a rock slammer, the stocks and 30s should be fine

I have a axle builder buddy that swears 65% of axle break while backing with the front axle locked. So don’t do that

I beat my 60 like a baby seal and didn’t break the 30s. Seen other snap them on what seemed like a bunny slope. YMMV

The left side axle snapped when PO's where slamming on it in reverse...just like your buddy says. The axles I am buying are a budget performance axle (made in India) from U.S Standard Gear made from 4340 steel, but not heat treated. They are supposed to be 25% to 30% stronger that stock OEM axles.

 

[nvrenuf]

I don’t think I’d spend the added money for 4340 and stay 30 spline, seems like turd polishing (no offense).

like bent suggested, I’d consider staying stock 30 spline. These are pretty strong and do well if you aren’t abusive.

Something else to consider is that the axle company probably has requirements for the joints with respect to breakage. You don’t want to give anyone the chance to point fingers elsewhere if something does break.

 

[1-ton]

I don’t think I’d spend the added money for 4340 and stay 30 spline, seems like turd polishing (no offense).

After doing some shopping on line the 4340 steel axles from U.S. Standard Gear are are cheaper than a set of Spicer OEM replacement axles. The 4340 axles from U.S Standard Gear are about $250 for a set of inner axles, and the Spicer's are about $275 for a set. The Spicers are only made of 4130 steel. They all pretty much suggest Spicer Liftime Series U-Joints.

 

[sweetk30]

your current hubs might let you just swap the axle gear end from the 30 to 35 spline .

if new hubs go yukon there stronger / slimmer / built off the 2 best design parts from dana 44 and 60 original spicer hubs . also if a yukon hub ever did fail it will default to locked . warn hubs dont do this . . .

i would go stock non neck down spicer inner shafts / spicer u-joints / spicer 35 spline dana 70 stubs for your intended use . the 30 spline outer is 1.31" dia and the 35 spline is 1.50" dia . your stock inners should already be non neck down so saved money there .

otherwise wheel it up . my info comes from wheeling and snow plowing in the north east over the past 20 years . and i still have my first dana 60 and its under its 4th truck now . i have tried to pop a shaft or u-joint on mine with a 9ft wide fisher snow plow on blasting donuts on snow / ice cover black top wheels turned full and still nothing .

 

[1-ton]

your current hubs might let you just swap the axle gear end from the 30 to 35 spline .

if new hubs go yukon there stronger / slimmer / built off the 2 best design parts from dana 44 and 60 original spicer hubs . also if a yukon hub ever did fail it will default to locked . warn hubs dont do this . . .

i would go stock non neck down spicer inner shafts / spicer u-joints / spicer 35 spline dana 70 stubs for your intended use . the 30 spline outer is 1.31" dia and the 35 spline is 1.50" dia .your stock inners should already be non neck down so saved money there .

otherwise wheel it up . my info comes from wheeling and snow plowing in the north east over the past 20 years . and i still have my first dana 60 and its under its 4th truck now .

From everything I have read my Dana-60 already has 35-spline inner axles (Left 35.1" long / Right 17.67" long), and 30-spline 12" long outer stub axles. Right know I have a set of nearly brand new 30-spline Mile Marker Premium locking hubs. I already have a set of Spicer Liftime Series U-joints sitting around for the axles.

Here is a link to the axles I am looking to buy.
http://www.usastandardgear.com/productdetails.aspx?ProdID=11619

 

[sweetk30]

run your inners and spicer joints .

see if mm hubs can get just the gear swapped to 35 spline cheep . if so grab the spicer outers and be don with it .

maybe modify the yokes of the shaft to take full circle snap rings to help from popping a cap maybe if you have the time and want for this mod .

this would be my game plan .

 

[1-ton]

run your inners and spicer joints .

see if mm hubs can get just the gear swapped to 35 spline cheep . if so grab the spicer outers and be don with it .

maybe modify the yokes of the shaft to take full circle snap rings to help from popping a cap maybe if you have the time and want for this mod .

this would be my game plan .

I am not sure what you mean? The left side axle on my Dana-60 is toast. My Dana-60 was pretty severely thrashed on by a PO. I should replace most everything, as long as I am doing a ring & pinion gear swap.

 

[sweetk30]

oh i didnt understand that . i was thinking you had one replaced already in the past .

in that case ether 1 new or good used replacement shaft for oem spicer or just get the newer stuff from us gear i guess .

i got a pile of 60 parts . i can check if i have a good extra non neck down inner if you want .

 

[1-ton]

Maybe I should start from the begining.

From what I can tell my Crew Cab was severely stuck one day by a PO in a wash in the desert. It was stuck in a wash that had water in it past its axles right up to its frame. The PO was in a panic, and started thrashing the truck trying to get unstuck. They appeared to be throwing it in forward and reverse at full throttle trying to get it unstuck. That blew out the left side front axle. I am now trying to fix that and install ring and pinion gears that will work better with the 37" tall tires.

 

[1-ton]

i can check if i have a good extra non neck down inner if you want .

Thanks for the offer, but I think my truck already came with the non-neck down outer axle stubs. I read something on Pirate4X4 that said starting in 1988 GM starting using the non-neck down outers on all Dana-60's, and now all after-market or stock Spicer replacements are non-neck down outers. My truck is a 1991 V3500.

 

[sweetk30]

80-81 they started .

i have a pile of shafts thats why i said i can see if i have a non neck down as i know i have a few neck down shafts .

never seen a outer that was 30 spline and not necked down .

 

[1-ton]

80-81 they started .

i have a pile of shafts thats why i said i can see if i have a non neck down as i know i have a few neck down shafts .

never seen a outer that was 30 spline and not necked down .

I was watching a youtube video that showed an old style outer Dana-60 axle that was necked down where the spindle roller bearing seal goes, and then showing the new stock Spicer replacement axle outer that did not neck down in that area. I saw other videos that talk about the neck down of inner axles as well right where the splines are located.

 

[sweetk30]

? got a link ? check your youtube history for it .

 

[Bent77]

I was watching a youtube video that showed an old style outer Dana-60 axle that was necked down where the spindle roller bearing seal goes, and then showing the new stock Spicer replacement axle outer that did not neck down in that area. I saw other videos that talk about the neck down of inner axles as well right where the splines are located.

Why not just replace the shafts with the stock Spicers? It’s probably your best bet. Some of the after market stuff is over rated

 

[Desert_K5]

For intended use, I'd go with stock replacements. There's a ton of R&D that comes along with OEM stuff that would be hard to match. ($$$$$)

 

[1-ton]

Why not just replace the shafts with the stock Spicers? It’s probably your best bet. Some of the after market stuff is over rated

One of the issues is availabilty. Those Spicer axles are not carried by a whole lot of people like the Yukon/US Standard Gear stuff, which is stocked by all the major on-line companies from Summit to Amazon to 4Wheel Parts.

P.S. Yukon and US Standard Gear are one in the same companies.

 

[Desert_K5]

https://www.dennysdriveshaft.com/c757_axles.html free shipping.