2004 SuperDuty Dana 60

DannyH

DannyH

smokey burnouts
Joined
Jan 10, 2014
Location
Stanfield, NC
Hey guys,
Looking into purchasing a 04 ford superduty dana 60 to swap into my cherokee. I have done a lot of research, but have come up with a few questions that I cannot find clear answers to.

-On the 2000- 04 SD dana 60 are the outer shafts 30 spline? if so, what can be done to run the generic 35 spline dana 60 outer shafts?
-Does this model of the dana 60 have vacuum hubs? if so, what is done besides removing the vacuum hardware to make it an all time lock?
-I know that these come with unit bearings in most models from what I understand. I plan to leave it at that but will i use a drive flange kit if swapping to the 35 spline shaft? Or is there something else that I will need? And will the drive flange kit bolt directly to the existing outer hub?
 
I have that exact model in my YJ so I should be able to answer most of that. 99-04 are all 30 spline outers and AFAIK, vacuum assist locking hubs. To convert to 35 spline outers you can either redrill the factory unit bearings or order some redrilled units with any lug pattern you want. They're expensive though.
 
I should also add that the special 35 spline shafts you'll need are also expensive. I'll probably run a 30 spline chromo outer and go with it.
If you can use a 05+ it's really the way to go.
 
What did you do about the vacuum locking mechanism? Does it always stay locked or how does that work?

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DannyH said:
What did you do about the vacuum locking mechanism? Does it always stay locked or how does that work?

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It still has a locking hub. If there's no vacuum going to it it works like any old locking hub. If you turn the hub to lock it locks manually, if you turn it to auto it's unlocked unless it gets vacuum.

Superdutys with a 4x4 stick shift (no knob on dash) had hubs that said lock and free, just like older trucks.

Ford just gave owners the option of manually locking the hubs due to a vacuum failure, or a farmer or oil field worker, who may just leave them locked always.

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My suggestion is to run regular dana 60 lockouts.

Warn Premium Locking Hubs 35 Spline for Dana 60

The 35 spline stubs are not that bad expensive.

FORD 60 CHROMOLY 35 spline- Outer Stubs Unit bearing Style

All you have to do then is have your unit bearings machined to accept the larger shafts. Any machine shop should be able to do this. I am working on one myself but I'm putting dodge unit bearing knuckle with for ttb rotor and hubs. BTW, ECGS has there lifetime shaft and joint kits for those axles too.

The 05 and newer axles are alot better axles, but I'm not sold on them yet. The lack of aftermarket shafts are what has me worried. Wheel a stock outer hard enough and it will brake. The only two companys making aftermarket shafts at the moment are RCV and CTM. Both mega money. Heck, RCV will make you a set with the rockwell bell that spline into the unit bearing with no flange, at a price of 3-5 grand. I think someone needs to just make chromoly outers. I think they would sell.
 
Yeah just that the 05+ axles aren't as easy to come by and I have an 04 Dana 60 lined up.so I think I will do that and run the original 30 splines while building everything else. Tha KS for the awesome info guys really helped!

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