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Old 02-04-2005, 01:53 AM
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Welding Dana 60

I realize someone is going to jump my *** for considering this but It will work until I get around to putting another Dana 60 (splicer 60) in, I'm currently working on this rear end, will be loads stronger (oversized high torque axles, spool, 7.17 gears)

I've been pondering this idea for a while now and decided I really need it (when I'm stuck in mud that is 3 feet deep and have to climb in when I need to attach the tow-chain to give you that little boost to get ya going again because I've got the tire getting all the power in the air spinning, kinda pisses ya off.

The truck has a Dana 60 (splicer 60) rear end in it. I know the axles are held in by the 8 bolts by the rim, do they slide out from there and if so are there any C-clips in there?

I'm also wondering if this was your truck would you pull the carier out of the ''pumpkin'' when you weld it or would you leave it in? Also leave the ring-gear attached or take the ring-gear off and weld.

What would be the advantages of pulling the carier and ring-gear off compared to leaving the ring gear on and welding in the ''pumpkin''?

Thanks for the help anyone can offer.
D200 Dodge

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Old 02-04-2005, 06:32 AM
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If you are going to exclusively use this truck off road we won't get on your case for welding up the spiders, and with 7.17 gears I don't forsee much pavement time anyway.

The axleshafts are bolted to the spindle with those 8 bolts and thats all you have, no C-clips or anything, your wheels and brakes are bolted to the rotor, which is held on to the spindle with two very large nuts and a lock.

I would pull the carrier out to be able to clean all the welding slag when I was done.

I would recommend looking over at Pirate 4X4's site and see what they have done, and the extensive explanations of the GM 14-bolt (you can use some of that info for your Dana 60), and their Dana 60 info too.
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Old 02-05-2005, 12:33 AM
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I'm not going to lie about this. I live about 14 miles away from our local "pit" (basically a 4 foot deep lake of mud). To get there I will take only back roads and will be inbetween my friends trucks in the ''trains'' as people call them that we go out in. There will be no other on-road driving.

Would you pull the ring gear off to avoid getting this spatter on it?

I'm going to look at Pirate 4X4's site right now so if I have any more questions I'll ask.

Thanks for the help,
D200Dodge
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Old 02-05-2005, 09:21 AM
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I have a welded diff (14B FF) under my 71K5. It isn't a daily driver but I have a long drive to get to anywhere with dirt/rocks/mud. I see nothing wrong with a welded diff on the street as long as you know what you are getting yourself into. Your rear tires will wear about 2x as fast as the front, you won't be able to make u-turns, pulling into parking lots or gas stations will suck, your tires will chirp (mine howl) when you go around corners.

Other then that it is alot more predictable they a locker. It won't unlock and then lock while cornering. You won't "change lanes" just from throttle application. You will also never have to ask your budies "are both the rear tires spinning ".

Because it is a FF axle you won't have to worry about getting the cross shaft out in order to remove it. In that case I would weld the spiders to the side gears, the side gears to the case, and the spiders to the cross shaft. Then just go ahead and fill in everything else with weld. You should pull the carrier out and the ring gear off to do it.

While you have the axles out count the # of splines on them. Many D60FF's only have 30-spline axle shafts. If that is the case don't waste any more $$$ on that axle. Go and look for a 14FF, or a D70 to put in there. The only problem with the 14FF is the lowest gears you can get are 5.13. Other then that they are cheep, easy to find, and very strong.
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Old 02-05-2005, 02:49 PM
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Ya, i'm building another dana 60 to put under my truck. 35 spline axles (possibly 40 if they have them).

This is just a temporary fix. I'm sick of getting stuck in the mud because one tire comes up out of it and that is the only one that gets the power.

I know what i'm getting my self into and I know what I should be able to get myself out of with it locked.

Thanks for the advice
D200Dodge
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Old 02-05-2005, 08:30 PM
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You won't be able to fit 40 spline axles in a D60FF. If it came with 30 (or the old 16) spline you won't even be able to run 35 spline because they won't fit in the hole in the spindle. The 35 spline ones come bored out bigger but there isn't enough meat left to bore them for 40 spline. I like my $100 14FF with factory 4.56 gears and 1.5" axle shafts
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