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Author Topic: Upgrading rear Dana 60 shafts. NEW SPINDLE INFO.  (Read 2944 times)

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Offline tv_larsen

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Upgrading rear Dana 60 shafts. NEW SPINDLE INFO.
« on: February 19, 2006, 05:54:46 PM »
I've been recently pricing some axle upgrades for the 60's in my RC, and one thing I want to do is upgrade the 30 spline rear axle shafts to 35 spline shafts.

I have a Dana 70 from a '91 CTD, so today I thought I'd pull the shafts and compare the lengths to see if they could be swapped into my RC's Dana 60.

The Dana 70 shafts are definitly larger than the 60 shafts, but they are the same length!



For giggles, I thought I'd check to see how much I'd be removing from the Dana 60 splindles to fit these axle shafts.

But they slid right in (albeit a little too snug for comfort)


I was sure that I had previously measured the ID of these spindles, and they were too small for 1.5" 35 spline shafts.  So I pulled them and counted, yep, these are 32 spline shafts. 

I didn't think Dodge started the 32 spline 70's until after '94, apparently they started much earlier.  When did Dodge start this?
« Last Edit: June 18, 2006, 12:57:50 AM by tv_larsen »
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Re: Upgrading rear Dana 60 shafts.
« Reply #1 on: February 19, 2006, 10:48:07 PM »
Rumor is that all the 3/4 ton CTD's got 32 splines probably even the single wheel 1 tons in the `89-93's, don't know about the duallies.
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Offline tv_larsen

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Re: Upgrading rear Dana 60 shafts.
« Reply #2 on: February 20, 2006, 12:10:20 AM »
Rumor is that all the 3/4 ton CTD's got 32 splines probably even the single wheel 1 tons in the `89-93's, don't know about the duallies.

Bummer, I guess this means the DRW 70's are 35 spline?  But they're probably a different length than the SRW 70's or 60's though?
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Offline trailduster440

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Re: Upgrading rear Dana 60 shafts.
« Reply #3 on: February 20, 2006, 05:48:22 AM »
I personally pulled a set of 35 spline axles out of a 89 CTD 2x SRW with 3.07 open rear.

Was the rear you pulled apart 3.55?

Those 32 spline axles are not quite as big if I recall.  I think they are just smaller then the 1.5 35 spline shafts.

You may be able to swap side gears and use these 32 spline shafts.  I know the dana 60 and dana 70 powerloc guts interchange with each other.

Will measure the spindles and 35 spline axles tomorrow.

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Re: Upgrading rear Dana 60 shafts.
« Reply #4 on: February 20, 2006, 08:08:25 PM »
This 32 spline Dana 70 was from a '91 W250 CTD with a 5/speed.  Gearing is at least 3.55, I haven't checked for sure, but I verified that the front was a 60, and not a 61.  The 32 spline shafts measured about 1.4".

I checked today, and Mt Logan Offroad (my local 4wd shop) will bore the spindles and can get 35 spline shafts for well under $100 each, so I'm just going that route.
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Offline Trailduster79

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Re: Upgrading rear Dana 60 shafts.
« Reply #5 on: February 22, 2006, 12:42:11 AM »
From what I hear some of the newer Dodges have the 32 spline rear 70 shafts too.

When you do bore the spindle, let me know how you do it.  I know there is a tool you can buy, but it is 300 bucks, and I haven't asked machine shops around here yet, but I am sure they will have a hard time boring the spindles since they would have to chuck the entire axle in a machine to do it.
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Re: Upgrading rear Dana 60 shafts.
« Reply #6 on: February 22, 2006, 01:01:59 AM »
Boring spindles wouldn't be too bad with a turntable horizontal boring mill... But not your everyday auto machine shop will have one of those...
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Re: Upgrading rear Dana 60 shafts.
« Reply #7 on: February 22, 2006, 02:34:03 PM »
With the exception of the post above, 3/4 ton cummins trucks only got the 32 spline axles.  Duallies got the 35 spline shafts, but they also got the 5/8 lug studs.  I cannot remember the length of the housing.

Its interesting as I understand the dana 70's used in the 1970's and 80's got the 35 spline shafts.  Nothing like making everything odd.

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Re: Upgrading rear Dana 60 shafts.
« Reply #8 on: February 25, 2006, 03:57:08 PM »
I had my D60 bored out this winter to accept the 35 spline shafts by a local shop.  Lets just say he was very creative with how he did it, and afterwards he told me he would never do that again until he had the real tools for the job :-) 
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Re: Upgrading rear Dana 60 shafts.
« Reply #9 on: February 25, 2006, 11:16:13 PM »
I had my D60 bored out this winter to accept the 35 spline shafts by a local shop. Lets just say he was very creative with how he did it, and afterwards he told me he would never do that again until he had the real tools for the job :-)

Mount Logan Offroad is going to bore mine.  They are getting the real tool to do the job.  I believe Randy's Ring & Pinion sells it for about $400.
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Offline Trailduster79

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Re: Upgrading rear Dana 60 shafts.
« Reply #10 on: February 26, 2006, 09:53:13 AM »
Mount Logan Offroad is going to bore mine. They are getting the real tool to do the job. I believe Randy's Ring & Pinion sells it for about $400.

Yeah, you west coast people are lucky having all the major fab shops out that way.....
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Re: Upgrading rear Dana 60 shafts.
« Reply #11 on: February 26, 2006, 02:18:36 PM »
Yeah, you west coast people are lucky having all the major fab shops out that way.....

We have trails to wheel on too.  ;)

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Re: Upgrading rear Dana 60 shafts.
« Reply #12 on: February 26, 2006, 03:19:49 PM »
But the trails are under 18' of snow at the moment. >:(

I wish spring would hurry up already. :P(highjack over)
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Re: Upgrading rear Dana 60 shafts.
« Reply #13 on: February 26, 2006, 03:49:54 PM »
Where are u getting 1.5" 35 spline shafts for under 100.00?
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Offline tv_larsen

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Re: Upgrading rear Dana 60 shafts.
« Reply #14 on: February 26, 2006, 03:59:55 PM »
We have trails to wheel on too. ;)

You mean we have public trails on public land. ;)

Where are u getting 1.5" 35 spline shafts for under 100.00?

I'm just going to buy mine through Mt Logan Offroad, but you can get them at Tellico 4x4 too. (check your length before ordering)
« Last Edit: February 26, 2006, 04:01:35 PM by tv_larsen »
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Offline z1bigtom

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Re: Upgrading rear Dana 60 shafts.
« Reply #15 on: February 26, 2006, 08:09:05 PM »
Sweet!    They sell 35 spline spools for 150.00 also.....Nice!

Thanks!!!! ;D
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Re: Upgrading rear Dana 60 shafts.
« Reply #16 on: March 6, 2006, 06:51:47 PM »
There is a guy on Pirate4x4 that is selling Yukon 35 spline shafts for 175 a set.  I am getting my shafts from him.

I found a local machine shop that will do the boring on my rear 60.  I am going to drop it off tomorrow and pick it up when I come back from spring break. 

I am going to pick up an open carrier that is 35 spline, and use it to break in my new gears, and then once the gears are broken in I am going to weld it up.

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Re: Upgrading rear Dana 60 shafts.
« Reply #17 on: March 6, 2006, 07:41:58 PM »
There is a guy on Pirate4x4 that is selling Yukon 35 spline shafts for 175 a set.  I am getting my shafts from him.

Cool, I think I'm getting the same shafts for about the same price from Mt Logan, they have extra long, rolled splines, and you just cut them to length.  Yukon claims they are 25% stronger than stock 35 spline shafts.
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Re: Upgrading rear Dana 60 shafts.
« Reply #18 on: March 6, 2006, 09:40:35 PM »
I hope they are alot stronger than the 30 spline shafts because I snap them like twigs.
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Re: Upgrading rear Dana 60 shafts.
« Reply #19 on: March 23, 2006, 12:26:11 AM »
Ok, I found a guy locally to bore my spindles, he did it for 100 bucks. 

I have also found a cheap source for the axle shafts. There is a vendor locally that sells them for 68 bucks each.  If anyone is interested in getting some from him let me know becuase I am going to be ordering mine before the end of the week.

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Re: Upgrading rear Dana 60 shafts.
« Reply #20 on: April 8, 2006, 05:22:35 PM »
Finally got my rear axle done.  Randy's R&P drug their feet for almost a month on sending the spindle boring tool, and never did send it. ::)  So finally, because of the time crunch, the axle housing was just pulled and sent to a shop in SLC for boring.  So the new gears and shafts are in.  Since Randys sent a 4.56 R&P instead of a 4.56+ spool I'm running a welded carrier for Jeep Safari, then I'll get the spool in later.

Randy's Ring and Pinion sucks.  :(  :)
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Re: Upgrading rear Dana 60 shafts.
« Reply #21 on: April 8, 2006, 07:38:04 PM »
Geeze, you must have made them mad or somthing! ;D

The two seperate occasions I ordered from them, they were great.
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Re: Upgrading rear Dana 60 shafts.
« Reply #22 on: April 8, 2006, 08:44:44 PM »
Sorry to hear about this. Did they so anything to make it right or just tell you so what.
Bummer you have to set up the diff again.

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Re: Upgrading rear Dana 60 shafts.
« Reply #23 on: April 8, 2006, 11:08:38 PM »
Sorry to hear about this. Did they so anything to make it right or just tell you so what.
Bummer you have to set up the diff again.

Luckily, I'm not the one dealing with them, this is the fabulous service they provided to the 4wd shop I'm buying the parts through.  We will see what they do on the spool.
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Re: Upgrading rear Dana 60 shafts.
« Reply #24 on: April 9, 2006, 06:27:28 PM »
Well, if you find a 60HD housing, you don't have to bore the spindles.

My 60hd housing measures 1.640 ID
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Re: Upgrading rear Dana 60 shafts.
« Reply #25 on: April 9, 2006, 10:35:34 PM »
Well, if you find a 60HD housing, you don't have to bore the spindles.

My 60hd housing measures 1.640 ID
My axle housing IS a 60HD, but the spindles were just a little over 1.4" ID.
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Re: Upgrading rear Dana 60 shafts.
« Reply #26 on: April 11, 2006, 08:11:13 AM »
I called Randy's about that tool, and they told me they were so backordered that I would need to call them in another month to see where they were.

I have mine just about completely done.  I just need to finish setting up my gears and it should be on the road.
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Re: Upgrading rear Dana 60 shafts.
« Reply #27 on: April 11, 2006, 07:45:35 PM »
TV, is yers a dodge 60hd ? from what I have been told, usually the dodge hd's have the larger spindle.

Anyway, I have found out that NO ONE makes a 4340 d60 rear axle unless it is semi float.

So i guess It'll be yukon axles for me too.
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Re: Upgrading rear Dana 60 shafts.
« Reply #28 on: April 11, 2006, 10:01:41 PM »
TV, is yers a dodge 60hd ?


Yes, it's a '78 Dodge Dana 60HD.  I also have a '75 Dodge Dana 60HD, it's spindles' ID are also too small for 35 spline shafts.

I'm curious, does your 60HD lack the "oval" bump on the top like trailduster440's in this thread?
http://ramchargercentral.com/boards/index.php?topic=66687.msg820474#msg820474
« Last Edit: April 11, 2006, 10:11:45 PM by tv_larsen »
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Offline ProjectPW

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Re: Upgrading rear Dana 60 shafts.
« Reply #29 on: April 14, 2006, 08:55:07 AM »
Hey TV I am getting a set of 60's on Monday. They are out of a '91 Dodge and the rear is an HD. I am plannining on pulling the shafts to inspect the brakes and count splines I will also measure the spindle ID for comparisons sake.
In the above link it appears that the lower picture has the ABS sensor. The axle I am getting does too. Maybe that is where the cases/spindles were changed????
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Re: Upgrading rear Dana 60 shafts.
« Reply #30 on: April 14, 2006, 12:21:04 PM »
Sorry I don't know how to copy address's but I'll try my best. The picture of TD440's axle a few posts ago looks a lot like a Dana 61 that I took out of an 85 ford. The # is cast in a different place than a 60 and you have to clean the crap out of a web to see it. They used 61's in Dodges as well.
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Re: Upgrading rear Dana 60 shafts.
« Reply #31 on: April 14, 2006, 04:23:48 PM »
61 will be clearly stamped in webbing between the housing and axle tube.  I thought HD 60s were 35 spline?

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Re: Upgrading rear Dana 60 shafts.
« Reply #32 on: April 14, 2006, 06:29:26 PM »
Damn it! I wish I wasn't so computer illterate or I would try and show a picture or somethin. The point I'm trying to make is the second picture in that old post was not a HD60 but a Dana 61 with likely 30 spline axles. They were not heavier axles, only the pinion was spaced out a bit to get a bigger pinion in. I think the ratio could get to 3.08 or 2.91 or thereabouts. Sorry to horn in if you knew that already.
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Re: Upgrading rear Dana 60 shafts.
« Reply #33 on: April 14, 2006, 10:39:19 PM »
Damn it! I wish I wasn't so computer illterate or I would try and show a picture or somethin. The point I'm trying to make is the second picture in that old post was not a HD60 but a Dana 61 with likely 30 spline axles. They were not heavier axles, only the pinion was spaced out a bit to get a bigger pinion in. I think the ratio could get to 3.08 or 2.91 or thereabouts. Sorry to horn in if you knew that already.




This is a 60HD with 4.10 suregrip all stock.  It is not a 61.  Please don't post incorrect information.  Thanks!

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Re: Upgrading rear Dana 60 shafts.
« Reply #34 on: April 14, 2006, 11:04:58 PM »
Hey TV I am getting a set of 60's on Monday. They are out of a '91 Dodge and the rear is an HD. I am plannining on pulling the shafts to inspect the brakes and count splines I will also measure the spindle ID for comparisons sake.
In the above link it appears that the lower picture has the ABS sensor. The axle I am getting does too. Maybe that is where the cases/spindles were changed????

I have a 1974 Dana 60HD rear here cast the same as the pic with the speed sensor. 

The rear will probably have 30 spline axles but the spindles should accept 35 spline axles.  If it has the round circle like TV's then it will NOT accept the 35 spline axles without boring the spindles.

Are these 4.10 gears?  They will be cast either 60 or 61.  You do not want a dana 61.

Study the pics and know that if it is a semi-HD like TV's you will have to bore the spindle to run the bigger 35 spline axles.

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Re: Upgrading rear Dana 60 shafts.
« Reply #35 on: April 14, 2006, 11:18:21 PM »
They are 3.54 geared axles out of a '91. The front is definately a D60 and the rear is a 60HD with a factory sure grip. The castings front and rear say 60. I got lots of pics. I bought them from KansasCrewCab76 (I think thats his screen name) lastweek.
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Offline trailduster440

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Re: Upgrading rear Dana 60 shafts.
« Reply #36 on: April 14, 2006, 11:38:06 PM »
They are 3.54 geared axles out of a '91. The front is definately a D60 and the rear is a 60HD with a factory sure grip. The castings front and rear say 60. I got lots of pics. I bought them from KansasCrewCab76 (I think thats his screen name) lastweek.

I think I remember those from the classifieds.  It is weird they are 3.55....Are they out of the same truck originally?  Most of the gas dana 60F trucks ran 4.10s IIRC.  Maybe the front was out of a diesel and the rear another truck or regeared.  Not that it matters except 3.55 is pretty high for a gas truck. You will probably regear etc.  Anyway, sounds like you got a good set of axles. 8)

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Re: Upgrading rear Dana 60 shafts.
« Reply #37 on: April 17, 2006, 05:56:44 PM »
I think I remember those from the classifieds.  It is weird they are 3.55....Are they out of the same truck originally?  Most of the gas dana 60F trucks ran 4.10s IIRC.  Maybe the front was out of a diesel and the rear another truck or regeared.  Not that it matters except 3.55 is pretty high for a gas truck. You will probably regear etc.  Anyway, sounds like you got a good set of axles. 8)

 He is only going to be running a 32-33 tall tire so the gears are fine for it. The axles look good i let him fill yall in on the measurements he took on it
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Re: Upgrading rear Dana 60 shafts.
« Reply #38 on: April 18, 2006, 09:59:21 PM »
I thought HD 60s were 35 spline?
Nope, rarely, perhaps never.  I've never seen a HD with 35 spline shafts.  Some have the big spindle I.D., some don't.  I've asked if anyone has ever found 35 spline shafts in ANY stock Dodge Dana 60 full floating rear axle, and no one has stepped up.  The info I have read says that 35 spline shafts never came in Dodge Dana 60 rear axles.
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Re: Upgrading rear Dana 60 shafts.
« Reply #39 on: April 18, 2006, 11:02:34 PM »
Ah.  I remember seeing on ebay a set of HD axles that were 35 spline, maybe they were out of a ford or something.  It didn't say what the axles came out of.

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Re: Upgrading rear Dana 60 shafts.
« Reply #40 on: April 19, 2006, 09:48:20 AM »
I have mine completely together now and have taken it out on the street a couple times. 

With the 35 spline shafts in it now, it doesn't load up as much going through corners with the welded rear end.  It is a lot less violent in parking lots now since the shafts don't twist.  It is much more predictable.  I am going to take it out this weekend wheeling.  probably won't notice much difference on the trail, but on the road it made a big difference in the driveablilty with the welded rear end.
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Re: Upgrading rear Dana 60 shafts.
« Reply #41 on: April 19, 2006, 01:16:41 PM »
Ok here is an up date on my HD60. The spindles measured 1.42" and it has 30 spline shafts. The sure grip feels nice and tight too. The 3.54 gears will work great with mt setup. I will be running 285/75/16 tires (33x11.5), and I have the benefit of a usable 1st gear in my NP445 tranny.
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Re: Upgrading rear Dana 60 shafts.
« Reply #42 on: April 19, 2006, 05:32:28 PM »
With the 35 spline shafts in it now, it doesn't load up as much going through corners with the welded rear end.  It is a lot less violent in parking lots now...

You know, I noticed this too, but I also changed tires at the same time so I wasn't sure if it was the shafts or the tires.
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Re: Upgrading rear Dana 60 shafts.
« Reply #43 on: April 19, 2006, 08:07:11 PM »
I am running the same tires as you, and it loaded up really bad before.  Those SX's grip asphault great after they have broken it.
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Re: Upgrading rear Dana 60 shafts. NEW SPINDLE INFO
« Reply #44 on: June 18, 2006, 12:56:46 AM »
New info to consider when upgrading a rear 60 to 35 spline shafts.

I was under the assumption that all Dana 60 spindles could be be bored large enough (about 1.60") to accept 35 spline shafts.  That is not true.

Today I was helping my brother swap the rear axle in his '77 W200 (a standard duty Dana 60).  The axle we swapped in was a standard duty Dana 60 from an '85 W350.  During the swap, I noticed that the spindles were NOT the same, as I had expected.

The '85 standard duty Dana 60 measured 2.00" at BOTH bearing locations.


The '77 standard duty Dana 60 measured 2.00" at the inner bearing, but only 1.80" at the outer bearing.  If this spindle were bored from the stock 1.42" I.D. to 1.60", the spindle would be FAR too thin.


A little more info.  Although the original rear axle from my brother's '77 W200 is known to be the factory installed axle, it seems to actually be a '76 Dana 60.  He knows this because the parts store listings for bearings and seals never fit, he has to buy parts for a '76 for them to fit properly.  The bearings listed for a '77 Dana 60 are actually the same as those listed for the '85.  So '76 must have been the last year for the smaller spindle, but can still be found in '77's.

I suppose I need to pull the shafts from my '75 Dana 60 HD and see if it too has the smaller spindles, or maybe this was the standard duty spindle only for those years.
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Re: Upgrading rear Dana 60 shafts. NEW SPINDLE INFO.
« Reply #45 on: June 18, 2006, 08:50:47 AM »
Nope, rarely, perhaps never. I've never seen a HD with 35 spline shafts.

     I have 2,  the factory rear in the crew that wasted the spindle that i had to change and get a new spindle for was 35 spl and a spare now.   The spare rear is also a 35 spl

      Get the bom # off your brothers rear and i'll tell you what year it is
« Last Edit: June 18, 2006, 08:52:58 AM by Evildriver-3 »
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Re: Upgrading rear Dana 60 shafts. NEW SPINDLE INFO.
« Reply #46 on: June 26, 2006, 07:24:00 PM »
My rear D60 was from a 77 Dodge, had the same outer diameter as the D70U sitting in my shop (anyone want to buy that cheap?) and the inner diameter was around 1.4.  There was plenty of spindle left when I had it bored out. 
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Re: Upgrading rear Dana 60 shafts. NEW SPINDLE INFO.
« Reply #47 on: June 27, 2006, 06:06:47 PM »
My rear D60 was from a 77 Dodge, had the same outer diameter as the D70U sitting in my shop (anyone want to buy that cheap?) and the inner diameter was around 1.4.  There was plenty of spindle left when I had it bored out. 

My '78 Dana 60 spindle was also large enough to bore out for the 35 spline shafts.  But aparently the '76-earlier (and apparently some early '77s) used the smaller spindle that isn't big enough.
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