Dana 60 Axle Splines?

[Badd F100]

Hi all, Im new here, have a 74 f100 2wd 4 speed, that I swapped f250 axles and 4x4 trans/t case in, as well as boxed the rails, and shortened the bed. I'm ordering spools and I was curious, how many splines are the 77 f250 dana 60 rear axles? Just curious as I would rather order the parts before I tear it down. I know I could just slide the axle out, but I am about 200 miles from the truck, and would like to order the stuff before I go out to do the swap. Thanks in advance,

-Christian

[averagef250]

Welcome to the site!

That's a toughy! 99% of the dentside highboy dana 60's are 16 spline, but there are 30 spliners mixed in now and then and to really throw you for a loop Ford used the Dana 61 rear axle under the later 70's 4x4's on a regular basis too. The Dana 61 is an odd duck and looks like a dana 70 from the outside. You'd say it was one except it doesn't say 70 on it anywhere and the ring gear is 9.75". If it were me I'd definitely pull an axle first.

On a good note though, If you do just say screw it and order parts, 30 spline is a safe bet. Even if it turns out to be 16 spline you can rob 30 spline shafts from any 73-79 F-250 2wd truck and bolt them in your '77 4x4 housing.

The 2wd to 4x4 conversion question comes up all the time on this site. If you ever get the chance you might take some chassis pics of your truck and post them up in the 4x4 section. I'm sure they'd get well used by guys trying to figure out how to do it themselves.

[Badd F100]

Welcome to the site!

That's a toughy! 99% of the dentside highboy dana 60's are 16 spline, but there are 30 spliners mixed in now and then and to really throw you for a loop Ford used the Dana 61 rear axle under the later 70's 4x4's on a regular basis too. The Dana 61 is an odd duck and looks like a dana 70 from the outside. You'd say it was one except it doesn't say 70 on it anywhere and the ring gear is 9.75". If it were me I'd definitely pull an axle first.

On a good note though, If you do just say screw it and order parts, 30 spline is a safe bet. Even if it turns out to be 16 spline you can rob 30 spline shafts from any 73-79 F-250 2wd truck and bolt them in your '77 4x4 housing.

The 2wd to 4x4 conversion question comes up all the time on this site. If you ever get the chance you might take some chassis pics of your truck and post them up in the 4x4 section. I'm sure they'd get well used by guys trying to figure out how to do it themselves.

Thank you, I was doing a little research on them but could not find anything like what year might come with which, i'll just wait I suppose. As for the 4x4 swap, I'll gladly post some pics up when I go out there. It wasnt that much trouble, but I have more tools then the average guy. Boxing the rails would have been 10 times harder without my plasma cutter and other metal fab tools. Hardest part was steering for me, took a while to figure out how to mount the different box. But it was not impossible. Took about a week straight. And it was definately worth the time, I cant believe what a difference just 1 more spinning tire does for traction. I cant wait for the spools.

Thanks for the help...

-Christian

[RedneckTexan]

Please post pics, I am wanting to convert my truck to a 4x4 as well and would love to see pics

BTW, Howdy from TEXAS and welcome to the site

[Badd F100]

Please post pics, I am wanting to convert my truck to a 4x4 as well and would love to see pics

BTW, Howdy from TEXAS and welcome to the site

No prob, just have to get out there to take some pics

As long as you have the ability to cut and weld you should be able to do it. It takes alot of measuring though..

[averagef250]

Preheating and the right rod make all the difference. You need an extremely low hydrogen specialty rod like 9018 to weld gears. Welding shops that carry specialty rods can usually set you up with the right stuff to get it done. If they tell you 70 series mig wire or 7018 rod will work walk out the door, that stuff will break in time. You don't have much to lose if you try it on the current carriers.

[Badd F100]

Preheating and the right rod make all the difference. You need an extremely low hydrogen specialty rod like 9018 to weld gears. Welding shops that carry specialty rods can usually set you up with the right stuff to get it done. If they tell you 70 series mig wire or 7018 rod will work walk out the door, that stuff will break in time. You don't have much to lose if you try it on the current carriers.

That is true, I might as well. Next mod, welded diff's. I have access to any rod I need. I even have some eutectic 120,000 psi specialty rod, but I'll pick up some 9018...

[RedneckTexan]

Please post pics, I am wanting to convert my truck to a 4x4 as well and would love to see pics

BTW, Howdy from TEXAS and welcome to the site

No prob, just have to get out there to take some pics

As long as you have the ability to cut and weld you should be able to do it. It takes alot of measuring though..

I should be able to do it, I'm handy with a welder and can read a tape