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Old October 31st, 2009, 09:42 PM   #1
camccardell
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Default sterling 10.5 front axle, Now a Build Thread!

Ok, I have seen a lot of cool custom front axles

a 609
a 14 bolt front (thanks Ian)

and a few others

Since ford sterlings are so friggin cheap, and I have a few and they are damm near bullet proof, I was thinking of making a steering axle for one.

I cannot seem to find a decent d60 for less than $1000, and I have a set of d60 ball joint inner Cs and some SD knuckes. I would rather use the older 97 down knuckes for the ease of the standard bolt pattern, but anyway...

I would like to get some measurements and information.

a pic of a d60 with a tape running across it would be most helpful.

The axleshafts in a d60 and sterling are the same right? 35 spline?

so if I cut the tubes and weld them the same, i could theoretically use the same axleshaft out of the year of the d60 that I was matching up right?

If anyone wants a set of d60 SD outer knuckles or wants to trade, let me know.

I think this will be a fun project for the winter.

Last edited by camccardell; January 16th, 2010 at 07:16 PM.
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Old October 31st, 2009, 09:45 PM   #2
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i'm curious to see where this leads. subscribed
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Old November 1st, 2009, 11:15 AM   #3
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i'm curious to see where this leads. subscribed
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Old November 1st, 2009, 04:48 PM   #4
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Should be the same as building a 14 bolt front, hardest part will most likely be getting seals to work.

PS Just bought a 79 Hp60 for $350 like 45 minutes from you You just need to keep your eye out for them
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Old November 1st, 2009, 05:39 PM   #5
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that is because you are awsome, and I am a plague carrier, lol

I have a sd d60, and this is what I am going to cut the inner c's off of. If is were complete I might not, but it is just a housing and knuckles.

I am unable to find my calipers. Anyone know the outside diameter of a sd d60 and a sterling 10.5 and 10.25 tubes?

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Old November 2nd, 2009, 07:17 AM   #6
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99-04 hp60 is 3.5"
05-present is 3.75" tubes
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Old November 2nd, 2009, 07:53 PM   #7
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that would make problem with me using the sd d60 inner c's then
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Old November 2nd, 2009, 08:26 PM   #8
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what's a 10.25? 3 1/8" or 3 1/4"

you could make a sleeve to make up the difference 3.5" .120 tube or whatever works
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Old November 4th, 2009, 11:17 PM   #9
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that is because you are awsome, and I am a plague carrier, lol

I have a sd d60, and this is what I am going to cut the inner c's off of. If is were complete I might not, but it is just a housing and knuckles.

I am unable to find my calipers. Anyone know the outside diameter of a sd d60 and a sterling 10.5 and 10.25 tubes?
Other than just being unique, why not just keep it simple??? Use what you have. With the time and money you are going to put into making the new axle, you can purchase remanufactured calipers from any parts store, and come out smelling like a rose. If you are concerned about the wheel pattern being metric, you can order a 8 x 6.5 bolt pattern unit bearings and put in a free spin kit.

I know its not my money to spend, just my 2 cents to throw into the pot.
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Old November 5th, 2009, 02:37 AM   #10
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stubs and shafts = $600
Ring, pinion and carrier $300
STD unit bearings $300 a piece
Calipers over $100 a piece

Free spin kit $???

too much damm money

also, I was told the tubs are bent on the d60 housing, but I sure as hell don't see it.
dosen't mean it isn't though.

My goal was to make this thing and the only thing I would have to buy since I have everything else is the axleshafts and some knuckles.
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Old November 5th, 2009, 08:11 AM   #11
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I am pretty sure you can use the 92-97 ball joint 60 knuckles and parts on the super duty inner c's.
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Old November 5th, 2009, 08:29 AM   #12
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Liv2mx might still have some 95? Ball joint knuckles still....I bought the shafts, but he might still have the knuckles.
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Old November 7th, 2009, 07:10 PM   #13
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gear question. will there be any problems with the gears? I ask because my friend said that they won't be meshing properly and I would need reverse cut gears.
I don't think so, but I am not a pro at this.

Any insight?
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Old November 8th, 2009, 09:09 AM   #14
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The gears work fine but since it is a low pinion axle the gears will be running on the "coast" side which makes them weaker. But so does a chevy/dodge front 60 that is why a Hp front is better.
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Old November 9th, 2009, 08:52 PM   #15
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Nobody has mentioned yet that the 35 splines are not the same. I figured this out when I tried swapping sterling for dana 70 shafts. They are both 1.5 inch 35 spline, but they are cut at a different angle, and will not slide into eachother. The sterling has wide cut steep splines while the 60/70 has narrow cut splines with less of an angle.
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Old November 9th, 2009, 09:32 PM   #16
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Quote:
Originally Posted by Jeepaholic View Post
what's a 10.25? 3 1/8" or 3 1/4"

you could make a sleeve to make up the difference 3.5" .120 tube or whatever works
No Both FF Sterlings 10.25, 10.5 use 3 1/2 OD axle tubes.
My 1996 D60 has 3 1/8" axle tubes.
2000 SD D60, and D50 have 3 1/2" tubes.

x2 what keithshotrodshop said about spline profile, spline count is only part of the match up.
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Old November 10th, 2009, 07:24 AM   #17
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No Both FF Sterlings 10.25, 10.5 use 3 1/2 OD axle tubes.
My 1996 D60 has 3 1/8" axle tubes.
2000 SD D60, and D50 have 3 1/2" tubes.

x2 what keithshotrodshop said about spline profile, spline count is only part of the match up.

Well he said it didn't look like they would work but that works prefect for the inner c's
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Old November 10th, 2009, 09:08 PM   #18
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so I'm cool on the inner c's and knuckles, just need custom axleshafts.

I wonder if there is a way to weld yokes to the sterling shafts....
I doubt it would be strong enough though...

hmmm
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Old November 11th, 2009, 07:58 AM   #19
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I know you said you have alot of sterling stuff. But with the outer stuff you have, you could just pick up a Dana 70 center and build a 70 front. That way you will have no shaft issues, and parts will be a little easier to interchange/find. I've got a bunch of 70 pumpkins myself, and will let them go cheap if you are interested.
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Old November 11th, 2009, 11:45 AM   #20
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i'd need tubes and axleshafts too.
I only have sterling axleshafts, and I'm not too sure I could press out the tubes from the sterlings....

thanks though
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