Dana 60

The Dana/Spicer Model 60 is an automotive axle manufactured by Dana Holding Corporation and used in OEM pickup and limited passenger car applications by Chevrolet, Dodge, Chrysler, Jeep and Ford and Land Rover. Various construction companies use this axle. There are front and rear versions of the Dana 60. It can be readily identified by its straight axle tubes, 10 bolt asymmetrical cover, and a "60" cast in to the housing. Gross axle weight ratings are often lowered by the vehicle manufacturer for safety and tire reasons. They are also lowered to reduce loads on other powertrain components such as transmissions and transfer cases. Dana 60 Axles are also increasingly swapped into many Jeep Wrangler Applications to accommodate larger tires and deep compound gearing with locking differentials.

Dana 60 Full Float(30 Spline, 4.10:1 gears, Limited Slip). From a 1999 4×4 Dodge 2500HD

General specifications

Every Dana 60 that was originally manufactured by Dana Corp (i.e. not aftermarket) is stamped with a build date and bill of materials on the back of the right hand axle tube.

Gross Axle Weight Rating (GAWR) 6500 lbs.
Ring gear measures 9 ³⁄₄".
OEM Inner axle shaft spline counts are 16, 23, 30, 32, 33 and 35.
40 Spline inner axle shafts and carriers are made for after market, high performance Dana 60 axles.
Pinion shaft diameter: 1.625"
Pinion shaft splines: 10 and 29
Gear ratios: 3.31:1 - 7.17:1
Carrier break: 3.31:1 - 4.10:1 and 4.56:1 - 7.17:1
Axle Shaft diameter
- 1.41” Front (32 Spline)
- 1.46” Rear (32 Spline)
Axle spline diameter
- 1.50” Front (35 Spline)
- 1.50” Rear (35 Spline)

Dana 60 front steer axle

History

In the mid-1970s the Big Three all started using this axle. GM began phasing it out in 1988 in favor of Independent suspension, while still offering it in some higher GVWR trucks (V-30) until 1991. Dodge used a Dana 60 up to 2002. 3rd Generation Dodge Rams dropped the Dana 60 in favor of AAM axles. Ford still uses the Dana 60 front axle. Manufactured in both Kingpin and Ball joint variations, "standard" (low pinion) and "reverse cut" rotation (high pinion) variations and open and limited slip, and locking variations. The housing material is Gray iron in early axles and Ductile iron in later axles. GM and Ford Dana 60 axles utilize locking hubs. Dodge Dana 60 axles utilized locking hubs until 1994 when a Center Axle Disconnect (CAD) system was adopted. However model year 2002 Rams phased out the CAD system leaving some 2002 Dana 60 axles permanently locked in.

Big Three variations

Ford versions are drivers side differential drop, reverse-cut gears, and kingpin knuckles up to 1991. The later axles have ball joints. Ford Dana 60 axles mostly feature 35 spline inner axle shafts, but some are 30 spline. Larger brakes and 35 spline outer shafts were made standard in 2005.
Dodge versions were passenger side differential drop, standard rotation gears, kingpin knuckles and 35 spline axle shafts in early models. The 2nd Generation axles were drivers side with ball joints. 30 Spline axle shafts were used instead of 35 splines, except 2000, 2001 and 2002 models which were equipped with 32 spline axle shafts.
GM versions are passenger side differential drop, standard rotation gears, kingpin knuckles and 35 Spline axle shafts.

Dana 60 aftermarket

The Dana 60 front axle has a great deal of aftermarket/third-party support, including many upgrades. Stronger axle shafts, Universal Joints and ball joints are widely available. As well as a large selection of traction control devices such as Locking differentials and Limited slip differentials. Axle shafts, Universal joints and carriers made from chromoly steel are even available. High capacity differential covers are available that increase the amount of oil the differential holds. These covers also feature Heat sinks that help keep the axle cool.

Dana Super 60 (Dana S 60)

Dana Super 60 from a 2008 Ford F-450

The Dana Super 60 is an upgraded version of the Dana 60 front axle.

Differences in the Dana Super 60 versus the regular Dana 60:

Larger and thicker diameter steel tubes (3.75 inches diameter and ½ in thick)
Larger ring and pinion which increase the contact area and overall strength.
Some use larger ("1550") Universal Joints which increase strength and steering angle.
Net formed spider gears for increased strength.
The Dana Super 60 housing is also found on 2005+ F250/F350, but the internals are 9.75" ring gear and smaller universal joint.
All made with 35 Spline axle shafts.

Dana 60 rear axle

The Dana 60 rear axle was first introduced in 1955 as a full floating axle in Ford F-250's and is still used today.

Manufactured in both full float and semi float variations. The semi float axles have GAWR up to 5,500 lbs and the full float axles were rated up to 6,500 lbs.
Full floating variants are common while Semi-floating axles exist, but are less common. Axle spline count varies, with 30 spline being the most common.

Dana 60 rear steer axle

Quadrasteer

Quadrasteer was an option in 2002–2005 GM full size, single rear wheel trucks. Constant-velocity joints were used instead of Universal joints.

Dana 61

A variation of the Dana 60 known as a Dana 61 was made to accommodate gear ratios that allowed for better fuel mileage. This was done as a direct result of the 1973 oil crisis. A 3.07:1 gear ratio was common for these axles and unachievable in a regular Dana 60. To allow for the different gearing, the Dana 61 had a greater pinion offset. This offset meant that a different carrier and a different ring and pinion had to be used.

Dodge Cummins pickups from the "1st Generation" that are not equipped with an overdrive transmission commonly have the 3.07:1 Dana 61 front axle because the higher gears are necessary to achieve reasonable road speeds at the low 2500 rpm governed speed of the Cummins engine in those pickups.

The Dana 61 was made in semi-float and full-float axles for select 4×2 and 4x4 Ford ³⁄₄-ton and 1 Ton Pickups and Vans from 1974 to 1987. A Dana 61 front axle was selectively used in Dodge 4×4 ³⁄₄-ton and 1 Ton pickups from 1987 to 1993. Although 3.07:1 and 3.31:1gear sets are common for a Dana 61, lower gear sets deeper than (4.10:1 on down) are not.

Some Dana 61's shared a common carrier with the Dana 60-Dana part #706040x (3.07-4.10)will interchange between the two. Dana part #706400 (3.07-3.54) shows in Dana's parts catalog to be Dana 61 only. The 706040x carrier can be purchased relatively inexpensively and used to install lower gears in a Dana 61 axle. Such as when replacing a broken or damaged Dana 60 with a Dana 61 while retaining the factory gear ratio.

Dana 53

The Dana 53 first appeared in the late 1940s and is much like a Dana 60. Although all Dana 53's are semi-floating, rear axles, 9.25" ring gear diameter. It was used as OEM in 1960s full-size (C-cody) Chrysler passenger cars equipped with the 440 CID engine. The Dana 53 was phased out in the late 1960s, replaced by the Dana 60.

Common Applications^[1]

Front Axle

International Harvester

1975 1300 Camper Special <-- A Dana BOM number series was created but no record of any Dana 60 front axles being used by International has been proven.

Chevrolet

1977–1991 1Ton (K30/V30)
1984–1988 Commercial Utility Cargo Vehicle

Dodge

1975–2002 ³⁄₄-ton (D-600/W-250/2500)
1975–2002 1 Ton (D-700/W-300/W-350/W-400/3500)

Ford

1974–1979 F-250 (Optional)
1999–2011 F-250 (Optional)
1979–2011 F-350 (Optional)
2000–2004 F-450/F-550

Dana "Super 60"

- 2005–2012 F-450/F-550
- 2011–2012 F-450(Class 3)

Kaiser/Jeep

1967–1969 M715/725/726

Land Rover - Dana 60 is known as Salisbury in the UK due to the manufacturing location of the Salisbury axle factory in the US). Dana bought Spicer and Salisbury, among others

1971–1977 Land Rover Series 2B Forward Control
1971–1977 Land Rover Series 3 1 ton (both front and rear axles)
1971–1985 Land Rover Series 3 Military Spec (rear on series III 109's)
1972–1978 Land Rover 101 Forward Control
1983–1998 Land Rover Defender 110

Military Spec

Rear Axle

Studebaker

1956–1964 E12 ³⁄₄t and E14 1t

Dodge

1966–1970 Coronet & R/T
1966–1972 Charger & R/T
1968–1972 Super Bee
1970–1971 Challenger
1963–1993 Dodge Ram 250 and 350
1994–2002 Dodge Ram 2500 (V8 Only)
2004–2006 Dodge Ram SRT-10

Plymouth

1966-1967 Belvedere
1966 Satellite
1968–1972 Road Runner
1967–1971 GTX
1970–1971 'Cuda

Ford

1955–1985 Ford ³⁄₄-ton Trucks
1955–1979 Ford 1 Ton Trucks
1980–2012 Ford E200/E250/E350 vans

Ford UK

1973–1982 Ford A0406 Truck (option)