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Old November 5th, 2005, 11:14 AM   #1
cornfed
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Default Dana Axle Info

This is not a complete list. If anybody has anything they would like to see added to this body of info (pics, applications, etc.) please PM me and I'll update the post.

Where to get part number on the axle:

Sorry for the crappy pic, but reading the arrows from left to right:
-ratio tag
-limited slip lubrication tag
-model number
-date
-Bill of Material

Where to find the application/build info:
Dana BoM Search Page


Dana 28 TTB
Donor Vehicles:BRONCO II FRONT 83-90, RANGER FRONT 83-90 ,93 & UP
Applications: Front
Axle Shaft Diameter: 1.0 Inches
Spline count: 23
Ring Gear Diameter: 6.625 Inch
Maximum tire size for stock axle: 31-inch
Strong Points: Light weight making it good for mud. Can easily be made to produce very good articulation with only the addition of longer radius arms and custom coils.
Weak Points: Outer axle shafts break. Radius arm bushings- especially passenger side frequently need replacing due to being too close to the catalytic converters. Brakes have a tendency to warp and/or crack the front rotors. Steering the stock steering set-up is very poor for a lifted truck. Severe bump steer is usually the result, in the higher lifts (4" and up)
More Info

Dana 30


Donor Vehicles:AEROSTAR 86-90, BRONCO & U100 67-71, IHC SCOUT F 67-74, JEEP C101 F&R 67-74, CJ5&CJ7 F 67-68, JEEP J10 F 66-88, WAGON.F 67-88, CHEROKEE 86-95, WRANGLER 87-06
Application: Front
Axle shaft diameter: 1.16 Inch
Spline count: 27
Ring gear diameter: 7.2 Inch
Maximum tire size for stock axles: 31-inch
Weak points: .......
More Info

Dana 35
Donor Vehicles:CHEROKEE REAR 84-97, COMANCHE REAR 86-92, WRANGLER REAR 84-97, WAGONEER REAR 84-97
Application: Rear
Type: Semi-floating
Axle shaft diameter: 1.16 Inch
Spline count: 27
Ring gear diameter: 7.56 Inch
Maximum tire size for stock axles: 33-inch
More Info

Dana 35 TTB

Applications: Front
Axle Shaft Diameter: 1.16 Inches
Spline count: 27
Ring Gear Diameter: 7.56 Inch
Maximum tire size for stock axle: 33-inch
Strong Points: Same knuckles and u-joints as Dana 44. 7.5" R&P are very strong. Have heard of virtually no failures. Can easily be lifted. Can easily be made to produce very good articulation with only the addition of longer radius arms and custom coils. Good aftermarket support, with many companies making lifts of all different sizes. Actually has hubs. Entire assembly is very strong
Weak points: Wheel bearings- though large, are placed too close together. Automatic hubs- prone to grenading, or giving up when you need them most. Also, only very coarse adjustment available for wheel bearings. Radius arm bushings- especially passenger side frequently need replacing due to being too close to the catalytic converters. Brakes have a tendency to warp and/or crack the front rotors. Steering the stock steering set-up is very poor for a lifted truck. Severe bump steer is usually the result, in the higher lifts (4" and up)
More Info

Dana 44 and TTB

Donor Vehicles:K10,25,30,35,F 60-80, C10 REAR 60-70, W100-350 F 69-96, F100,150 4X4 R 67-78, F150,F250 F 75-90, F100,F150 F 78-90, IHC SCOUT 74-80, 86 CJ7 Rear
Applications: Front and rear
Type: Mainly semi-floating, although there were some very rare full-floating units
Axle Shaft Diameter: 1.30 Inches
Spline count: 30 (after '72; prior to '72, some were 19-spline)
Ring Gear Diameter: 8.5 Inch
Factory ratios: 2.76:1 through 5.89:1
Maximum tire size for stock axle: 35-inch
Weight (solid axle): 240 Pounds
Strong point: Wide availability and significant aftermarket support in parts and upgrades
Weak point: Carrier and spider gears, U-joints, ring-and-pinion
Junkyard jewel: Find a front axle out of an early '80s Dodge 3/4-ton because they were equipped with locking hubs. Also, a front axle out of a '76-or-earlier ½- or ¾-ton Chevy has steering knuckles that are cast flat and easily adaptable to crossover steering
Building secrets: Upgrade the stock carrier and spider gears because they're notoriously weak. Also, if you've indexed the axle to improve pinion angle, use a diff cover from a '78 or '79 Ford ¾-ton high-pinion '44 because it allows for a larger quantity of lube and a higher fill point
Aftermarket alternatives: Currie Enterprises, Custom Differentials, DTS Custom Service, Dynatrac
Notes: They came in both low-pinion and high-pinion models, and the centersection was even used in '80-and-up Ford Twin-Traction-Beam applications. They were offered in 5-, 6-, or 8-lug bolt patterns.
More Info

Dana 50 TTB

Donor Vehicles:F250 & F350 FRONT 78-97
Applications: Front
Axle shaft diameter: 1.31 Inch
Spline count: 30
Ring gear diameter: 9.25 Inches
Maximum tire size for stock axles: 36-Inch
More Info

Dana 60

Donor Vehicles:K30,35 F 77-91, W200 250 F&R 69-93, W300 350 F 75-93, F100 R 67-85, F250 F&R 67-88
Applications: Front and rear
Type: Semi- and full-floating
Spline count: 16, 23, 30, 32 and 35
Factory ratios: 3.54:1 through 7.17:1
Maximum tire size for stock axle: 38.5-inch
Weight: 505 Pounds
Strong point: Available in a variety of widths, most of which were full-floaters
Weak point: The driver-side carrier bearing was known to spin on the carrier and this often spun the race, which can damage the housing
Junkyard jewel: A heavy-duty front '60 can be found on '78 and '79 ¾-ton Ford pickups equipped with the snowplow package. Some late '70s and early '80s Dodge trucks had 35-spline '60 rear axles. Rear '60s are easy to find
Building secrets: The spider-gear roll pin is small and hollow, and is prone to breakage. Builders often double up the roll pin for extra strength (slide one inside of another). Also, replace the pinion yoke with a 1350-series yoke for extra strength. Finally, be careful about the spline count. Look for the 32- and 35-spline axles, avoid the 16s and 23s
Aftermarket alternatives: Currie Enterprises, DTS Custom Service, Dynatrac, Custom Differentials
Notes: The venerable '60 has been available in either high- or low-pinion designs and was never used in an IFS application. Custom Differentials warns to steer clear of the rare but virtually identical Dana 61 because most of the parts are not interchangeable
More Info
Dana 70

Donor Vehicles:...
Applications: Front and rear
Type: Most full-floating with some rare semi-floating in commercial applications
Spline count: 23, 32 or 35
Factory ratios: 3.54:1 through 7.17:1
Maximum tire size for stock axle: 44-inch
Strong point: Large teeth on ring-and-pinion
Weak point: Small diameter pinion shaft (same as found on Dana 60)
Junkyard jewel: Rarely seen but known to exist are open-knuckle front axles with disc brakes. A rear heavy-duty '70 was fitted under '73-'91 Chevy dualie pickups, and it has larger-than-normal carrier bearings
Building secrets: When rebuilding, make sure that any stock oil-restricting device is left in the pinion area. This keeps lube in the pinion-bearing area at a higher level and retains it longer. Custom Differentials says that a number of '70s come to them with the oil-restricting devices removed
Aftermarket alternatives: Dynatrac, Custom Differentials
Notes: One of the benefits to a '70 is that there are a number of different pinion yoke sizes available, including a 1410-series yoke. Be careful though, because different housing castings used different sizes of pinion bearings due to different sizes of pinion bores
More Info

Last edited by cornfed; November 5th, 2005 at 01:43 PM.
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