Axle Spline Count Dana 60 Front Axle 2002 2500 4 x 4

[Chief USA]

I am in the process of ordering a front and rear Eaton TruTrac for my 2nd gen 2002 2500 4 x 4. I replaced the differential covers and have the axle tags in a box "somewhere" but have not been able to remember where I "professionally cataloged" them away.

From the research I have done, as best I can tell, chances are that the rear Dana 80 axles has 35 spline axle shafts and the correct Eaton TruTrac would be Eaton Part # 915A567 since I have 3.54 gears. I would appreciate verification on this or correction to the correct part #.

The front Dana 60 is what I am having a bit of trouble with. In some places I have read that in model year 2002 Dodge phased out the front axle CAD system and the front axle is permanently locked (which mine is). In some places I am reading the front axle shafts are 32 spline and others say 35 spline.

I downloaded the Eaton Application Guide (see link below) and according to the information in the guide the correct part # is 915A387. The Eaton Application Guide states that this particular TruTrac is for 35 spline axles on page 8.

https://www.eaton.com/content/dam/e...ormance-differential-application-guide-en.pdf

I crawled up under the truck in hope that the Dana BOM (Bill of Materials) might be stamped on the axle tubes but did not see any.

Has anyone installed Eaton TruTracs in a 2002 Dodge Ram 2500 like mine and if so, what was the axle spline count on the front and rear axles. I want to make sure I order the correct TruTracs the first time so as not to have a big hold up returning and re-ordering the correct TruTracs after axle disassembly.

Thanks in advance for help and recommendations.

 

[BigPapa]

Your stock front axles are 32 spline.

For the rear, I don't see in your signature if your truck is manual or auto. Auto came with the Dana 70, manual had the Dana 80. The Dana 70 has 32 spline axles and the 80 has 35 spline axles.

 

[Chief USA]

Your stock front axles are 32 spline.

For the rear, I don't see in your signature if your truck is manual or auto. Auto came with the Dana 70, manual had the Dana 80. The Dana 70 has 32 spline axles and the 80 has 35 spline axles.

Thanks! My signature would only allow so much. I have the 5.9 HO version that came with the NV5600 transmission. I have the Dana 60 in front and Dana 80 out back. Glad I waited to get some accurate information as I was thinking about taking a chance and making the order. So now I am faced with the conundrum of which if any front axle limited slip/locker to get.

This also raises the question, is it possible to upgrade from the 32 spline axles to 35 spline axles with this particular Dana 60. In 2002 Dodge eliminated the CAD system on the front axle and built this model year truck with a permanently locked front axle. If it is possible, how much difficulty and cost is involved in making the upgrade?

If at all reasonably possible, I REALLY want the Eaton TruTrac front and rear.

 

[Chief USA]

On further research it appears that the Eaton TruTrac for the front axle is an economic non-starter. It IS possible to install a front Eaton TruTrac in a Dana 60 on this model year truck but it would require upgrading to 35 spline axles and 35 spline flanges or 35 spline hubs in addition to the TruTrac differential.

Apparently the 32 spline dana front axles in this model year truck has very little after market support and about the only traction aid I could find is the Yukon Gear & Axle YDBD60-3-32 Dura Grip Positive Traction unit Part # RRYDGD60-3-32.

Which I am not all that sure would work very well.

 

[BigPapa]

I would call Randy’s Ring and Pinion, I think it’s now Randy’s World Wide. Diffs are there specialty. If they don’t have it or know about it, it’s not out there.

 

[BigPapa]

This fellow just posted this over on CompD in case you’re interested. I have no idea if it’s a deal or not.

D80 Eaton trutrac 35spl. New, installed for setup, customer couldn’t afford bill. 550$ shipped! Pm or txt 920-382-3312

Thanks
Matt

 

[Chief USA]

Can you send me a link?

 

[Chief USA]

Nevermind, I found it and sent a PM.

 

[BigPapa]

The 35’s are out there for your 60. We put them in the pulling truck. I believe Joe got them from Haisley Machine but I’m not sure. I would start with Randy’s.

 

[Chief USA]

The 35’s are out there for your 60. We put them in the pulling truck. I believe Joe got them from Haisley Machine but I’m not sure. I would start with Randy’s.

Many thanks! I sure appreciate the help. As popular as our trucks are or once were, you would think there would be more aftermarket support for things like this.