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Old September 9th, 2010, 05:25 PM   #1
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Default Good breakdown/reference for newer Ford Bal Joint Dana 60s?

Thinking of doing a hybrid axle for the '6, and am thinking of a BJ/Unit bearing Ford unit for parts.

The pirate D60 bible doesn't really touch the newer ball joint stuff. I've seen some good references before on tube sizes, spline counts, etc, but I can't find them now..
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Old September 9th, 2010, 05:34 PM   #2
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99-04 3.5" tube 30 spline stubs 35 spline inners
05+ 3.75" tube 35 spline stubs and inners
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Old September 9th, 2010, 06:22 PM   #3
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Hmm, 0.500" wall tubes?

So I could just lop off the knuckles leaving the old tube pressed/welded in, then bore the old tube to 3.00"ID, and slip them onto a new center with 3.0" tubes.....

And the unit bearing can be disassembled and bored to 1.5", correct?


You can pick up the 99-04 fronts for cheap.
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Old September 9th, 2010, 07:10 PM   #4
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the 99-04 are ~3/8" wall, yes you can bore them for 35 spline or just get new ones from branik in 5,6,8, and the metric already bored for the 99-04 style

You can also use 92-97 inner c's and run the superduty knuckles if you need a smaller diameter

the 05+ are .5" wall
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Old September 9th, 2010, 07:33 PM   #5
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Got a lathe, figured I'd see if I could bore and turn them to be 5 on 5.5 myself..

*IF* I do that, which I might not ever get aroudn to, anyway.

I hate 36-37" tires. D44s are borderline, D60s are too big...
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Old September 9th, 2010, 07:40 PM   #6
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Agreed on that, nice size tire not a easy axle choice.

Sounds like the JK 44's can handle them with some upgrades though
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Old September 9th, 2010, 07:43 PM   #7
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Originally Posted by Jeepaholic View Post
Agreed on that, nice size tire not a easy axle choice.

Sounds like the JK 44's can handle them with some upgrades though
I have an HP44 with 5.13 gears already, so I might just retube it to work with what I need, and run that with CVs and 30 spline flanges.
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Old September 9th, 2010, 07:46 PM   #8
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Did you see the JANA 54 thread on pirate? He has a setup to run the dana 50 gears in a hp44, but since your geared already might not be worth it.

Sounds like you might as well run what you have and go from there
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Old September 9th, 2010, 07:56 PM   #9
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Hp44 center with superduty balljoint outers. Budget but nice and strong.

Check out the latest crawl (24) for a good breakdown of using super duty bj outers. The nice thing is, you can use one of the useless d50s
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Old September 9th, 2010, 08:23 PM   #10
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What shafts, then, do they mkae 35 spline side gears for D44 lockers?
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Old September 9th, 2010, 08:52 PM   #11
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I remember arb making a 35 spline diff. You might ask scooter built what he ran in his 4460? Mac at C&M machine can broach your side grears if they have enough meat also.

Lots of options....

I'm not positive but I'm pretty sure the d50s have the same knuckles as the d60s but come with smaller shafts. Ie, run 60 sized shafts in the knuckles. Can anyone more familiar with them confirm or deny that?
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Old September 9th, 2010, 10:00 PM   #12
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Quote:
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Hp44 center with superduty balljoint outers. Budget but nice and strong.
Why not just run a stock D50 at that point?
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Old September 9th, 2010, 10:01 PM   #13
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Quote:
Originally Posted by 95geo View Post

I'm not positive but I'm pretty sure the d50s have the same knuckles as the d60s but come with smaller shafts. Ie, run 60 sized shafts in the knuckles. Can anyone more familiar with them confirm or deny that?
Dana 50 superduty and Dana 60 superduty use the same Cs, knuckles, brake hardware, etc.

I have a few extra sets of Cs and knuckles if you are looking to buy a set.
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Old September 10th, 2010, 06:50 AM   #14
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If I go this route, I had been planning to build a 609 axle, to match the rear 9". If I went with a 44/60 hybrid, its *only* because I have already a HP44 with the gears and locker in it.

BJ 60s of the 99-04 variety can be had for $400 or less at many recyclers, so I figured buying a complete one would be the most economical, rather than piecemealing knuckles. How much do you want for the knuckles + inner Cs, etc, Bones?
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Old September 10th, 2010, 07:26 AM   #15
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Quote:
Originally Posted by 95geo View Post
I remember arb making a 35 spline diff. You might ask scooter built what he ran in his 4460? Mac at C&M machine can broach your side grears if they have enough meat also.

Lots of options....

I'm not positive but I'm pretty sure the d50s have the same knuckles as the d60s but come with smaller shafts. Ie, run 60 sized shafts in the knuckles. Can anyone more familiar with them confirm or deny that?
I built Scooter builts axle, 35 spline arb a cam seal for some truck for shaft seals, short side was a stock 90's era hp60, used a F-250 hp44 for the 3"tubes and sleeved the 92-97 ball joint inner c's, long side was just a cut down spicer shaft.

A 50 uses 30 spline inners so you could use those, or you can get a 33 spline detroit or ox locker also. I found a seal for the 33 spline setup but have to find where I wrote it down
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Old September 10th, 2010, 09:26 AM   #16
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Quote:
Originally Posted by Haggar View Post

BJ 60s of the 99-04 variety can be had for $400 or less at many recyclers, so I figured buying a complete one would be the most economical, rather than piecemealing knuckles. How much do you want for the knuckles + inner Cs, etc, Bones?
Unfortunatly their prices have been going up

I'll see what parts I have left over and shoot you a PM. I can't remeber exactly how many spare sets I have left. Any interest in the BJ60 axleshafts inners and outers? I have those for sale and have no need for them.
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Old September 10th, 2010, 09:45 AM   #17
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Quote:
Originally Posted by Bones View Post
Unfortunatly their prices have been going up

I'll see what parts I have left over and shoot you a PM. I can't remeber exactly how many spare sets I have left. Any interest in the BJ60 axleshafts inners and outers? I have those for sale and have no need for them.
Hmm,, yeah price whatever you have, knuckles, unit bearings, locking hubs, shafts, whatever.

www.car-part.com, I can find a dozen complete axles under $400 in MI. Usually $400-$500 in the yards in flint near me...
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Old September 10th, 2010, 09:52 AM   #18
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Quote:
Originally Posted by Haggar View Post

www.car-part.com, I can find a dozen complete axles under $400 in MI. Usually $400-$500 in the yards in flint near me...
How can you tell they are 60s? most are 50s.

Are you going high-steer or using the stock steering arm location?
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Old September 10th, 2010, 01:49 PM   #19
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I have some 03 d60 knuckles I'd let go for $150 if you are interested
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