Front axle upgrade

[2Farr]

It all started out as a free wheel hub upgrade. Well that made a left turn very fast. No one makes free wheel hubs for a 1999 dodge that had ABS on the front axle. So I purchased a 2002 front axle off a low milage 3500. I took it all apart and installed new bearings and seals in the diff. Installed some EMF ball joints. Installed a set of spyntec hubs for a dually which gets rid of the factory hub extension. New calipers and rotors. The next problem is the 2002 Y steering set up. I could not use my 99 steering because of the taper and hole size were different in the knuckles. I opted to go with the 2003 T style. This bolted right up to the 2002 axle, except for the pitman arm. My 1999 pitman would not work unless it was reamed out. I found that a 2002 pitman are would work so that is what I did. At the end of the day this project turned very good. Hubs work, as do the ABS system. The new two piston calipers stop better than the single piston setup. I found with the build some very interesting differences between the 1999 dana 60 axle and the 2002 dana 60. One is the ring gear on the 2002 axle is 10.5" larger than the one that came with my 99. The axle shafts are about 1/4" bigger in diameter. You can see from the seal pic. The 1999 axle tubes are 3 3/8" in diameter while the 2002 is 3 1/2" It took about a week to complete. Would I ever do this again? I would have to think about it.

 

[Matt42]

Wow. Nice looking work. Have you considered writing up a pictorial for the print TDR?

 

[NIsaacs]

One is the ring gear on the 2002 axle is 10.5" larger than the one that came with my 99.

First of all, dang fine job and info! However, can you explain the above statement? Is that a typo or....D-60 is 9.750"....D-70 is 10.5".

Looking at the wheel/hub picture. The wheel is aftermarket I assume and is stud centric. Is the hub also hub centric, will the oem wheel fit? What is the stud size? Are they 9/16's"? Don't take my questions as doubt in your ability, but just using the picture, I have questions.

The nuts appear to be too deep, like they are too small for the wheel. Will that wheel fit a 5/8" stud? What is the degree of taper on the nuts/wheel?

 

[2Farr]

From what I can find is that a Dana super 60 and the Dana 70 have a 10.5 ring gear while the Dana 60 has a 9.75 ring gear. This axle did have the 35 spline shafts also.
The lug studs are 9/16 - 18 so they are standard Dodge. They have been on the truck for 150k miles so they work and I have not had any problems with them. As you can see from the pic the contact area on the factory lug nut and the ones that are on the truck are the same. The hubs were built by Spyntec. They make them for Chevy, Ford and Dodge. I chose the Dodge ones so any Dodge rim will fit.

 

[NIsaacs]

So what axle do you think you have? Dodge, Ford or GM

It appears the F250/350 uses the Super 60 housing but uses the 9.750 ring gear and the F-450/550 uses the 10", I didn't find a 10.5" Super 60, which don't mean much.

I did find this:

https://r.search.yahoo.com/_ylt=Awr.../Dana_60/RK=2/RS=1NaDOsbmHYqGCGiEiGAApHDaT2w-

And this:

https://www.axlebuilder.com/dana_60_front.html#collapseFour

 

[2Farr]

This explains better.
https://lugnut4x4.com/axles/14-bolt-vs-dana-60-dana-70/#.X_vizAKKRCU.mailto

 

[NIsaacs]

One is the ring gear on the 2002 axle is 10.5"

This is the part that bugs me. I have been around Dana axles forever and built lots of them. I have never seen or heard of this. Even the Super 60 maxes out at 10". With some housing massaging, the 10" ring gear will fit the standard D-60, but 10.5"??

 

[2Farr]

We did pull it out of a clapped up farm truck in Missouri. Who knows it's real history.

 

[JMcCoy]

Nice work. Was it pulled from a Dodge? I hope you put the massive 3rd gen brakes in it. Does it have a CAD? The reason I ask is that I have a late 02 Non-CAD Dana 60 I'm thinking about building. It would be nice to know it already had 35 spline axles. The only thing that's stopping me it that I've already dumped a ship-ton of $ in the axle already in the truck.

 

[Cummins12V98]

3rd gen brake Mod on my 01 Sport is AWESOME.

 

[2Farr]

A non cad axle will turn your transfer case all the time. Also the front driveline will spin all the time. Your fuel milage will suffer. If you'r going to build a non cad front axle on your rig you might consider installing some free wheel hubs also. As far as the brakes go, I don't think I can go much bigger.

 

[Cummins12V98]

3rd gen brake mod requires a minimum 17” wheel.

 

[SnoKing]

A non cad axle will turn your transfer case all the time. Also the front driveline will spin all the time. Your fuel milage will suffer. If you'r going to build a non cad front axle on your rig you might consider installing some free wheel hubs also. As far as the brakes go, I don't think I can go much bigger. View attachment 126423

Also a 2002 will drive with a bit heavier steering vs the CAD equip'd truck.

 

[JMcCoy]

I understand what the CAD does. The reason I want to build the non-cad axle is to get rid if the cad housing and for the larger 3rd Gen brakes. I've had 35 spline one-piece CAD-delete axles and free-spin hubs for years. I was just wondering what axle you put in.

 

[2Farr]

You could re tube the axle you have now. It's a little welding but not rocket science to do. While your at it you could truss the housing too.

 

[JMcCoy]

2Farr, I appreciate the suggestions, but you haven't answered any of my questions about your axle. I was just trying to get a little information without high jacking your thread (too late).

I have a '02.5 non-cad axle (rarer than hens teeth) sitting in my garage that I am going to build. I have a highly built axle under my truck. It has Yukon 35 spline chrome-moly cad-delete axles, ARB air locker, 4.10 Yukon gears, Ford knuckles, spindles, hubs, and brakes, Yukon 35 spline outer stub axles, and Yukon hub locks. The axle is awesome and the Ford brakes are WAY better than the 94-99 Dodge. I also have an '02 disk brake Dana 80 in the truck. With no proportioning, I have too much rear bias causing the rear brakes to lock up easily. Yes a proportioning valve would help, but I would like the system to be better balanced first. Front brake choices:
94-99 Dodge (1 piston) 12.25"
92-94 Ford (2 piston) 12.25" (current)
95-97 Ford (2 piston) 12.75" (have knuckles)
00-02 Dodge (2 piston) 12.85"
03-18 Dodge (2 piston) 14.10" (huge and will bolt right up to the "00-02 axle).

I'm trying to decide whether to sell the '98 axle built (have to find a buyer), or scavenge the parts to build the 02.5 (would be a shame). Again, I wasn't trying to high jack the thread with too much information. Just looking for a little information. Thank you

 

[2Farr]

Sounds like your system is out of balance. You need to take a pressure check at your calipers. Two easy ways to get a system to work . One is to put a proportioning valve in line. The second is to go to a bigger (or smaller) piston size on the calipers. The early 2nd gen trucks had a proportioning valve that self adjusted to the load in the bed of the truck. My self I'd just install a adjustable proportioning valve. You have a lot of parts to choose from.

 

[JMcCoy]

Nice work. Was it pulled from a Dodge? I hope you put the massive 3rd gen brakes in it. Does it have a CAD? The reason I ask is that I have a late 02 Non-CAD Dana 60 I'm thinking about building. It would be nice to know it already had 35 spline axles. The only thing that's stopping me it that I've already dumped a ship-ton of $ in the axle already in the truck.

I'm fully aware how my brake system works. That's why I want the huge 3rd/4th gen brakes. You still have not answered any of my questions about YOUR axle. I give up.

 

[Ozymandias]

From my sight he provides all information about the axle in his first post all the way up at the top.

 

[JMcCoy]

Really? Your site must be better than mine. Maybe you should read his post then read my questions.

He states his axle has a 10.5 inch ring gear. Dodge never had a Dana 60 with 10.5 inch ring gear. He said his axle had 35 splines. I asked whether or not if he had a CAD axle. In the photo, it appears it does, but I cannot tell for sure. 00-02 CAD axles had 32 spline. I'm not sure what spline the late-02 non-CAD axle had, hence the reason for my questions. If it has a CAD, it did NOT come with 35 spline axles. Did he actually measure and count the splines or just read about it?

All I wanted to know was if he had a CAD or non-CAD axle. It would be nice to know if the late-02, non-CAD, axle in my garage already had 35 spline axles without breaking it apart and stinking up my garage.

Again, not trying to make this about me. 2Farr obviously did a nice job. I just had a couple simple questions. That's it. Forget it, I'll just take mine apart. Thank you for chiming in though.