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Upgrading rear Dana 60 shafts. NEW SPINDLE INFO.

8K views 47 replies 15 participants last post by  tv_larsen 
#1 ·
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?
 
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#2 ·
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.
 
#3 ·
Flake said:
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?
 
#4 ·
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.
 
#5 ·
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.
 
#6 ·
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.
 
#8 ·
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.

Michael
 
#9 ·
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 :) 
 
#10 ·
TN_Dodge said:
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.
 
#11 ·
tv_larsen said:
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.....
 
#13 ·
But the trails are under 18' of snow at the moment. :mad:

I wish spring would hurry up already. :p(highjack over)
 
#15 ·
SpiderRam said:
We have trails to wheel on too. ;)
You mean we have public trails on public land. ;)

z1bigtom said:
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)
 
#17 ·
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.

 
#18 ·
Trailduster79 said:
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.
 
#20 ·
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.

 
#21 ·
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.  :(  :)
 
#24 ·
SpiderRam said:
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.
 
#26 ·
TheRamChargerMan said:
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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