Dana 60 FDU ....FITS with Extensive Modifications!!!

[BigMeatsBronco]

I figured you would have used a new piece of tube and a unit bearing or something that would allow you to up size the intermediate shaft.

There's no need to upgrade that intermediate Spicer cast iron tube, it already has the bearing inside that is big enough for the 35 spline shaft. I do intend on putting a ball bearing out on the end of it for extra support although the roller bearing inside is probably a adequate. The 35 spline shaft I have already fits perfectly in the tube with the original bearing

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[Snacktime]

So what your running cost tally so far? This looks pretty reasonable so far.

 

[BigMeatsBronco]

So what your running cost tally so far? This looks pretty reasonable so far.

The biggest cost will be the inner custom stub axle(s), and the 934/5 CV joints. I'm getting quotes...

so far this is what it takes.

HP Super 60 casting for 10" gears, ....$750
custom Machine work... $1000
stub axle bearings ......$120
35 spline E-locker ... $1388
Ring & pinion gears... $405
Bearings and installation kit...$250
labor to set up gears...$400?
custom cover plate with mount...$300
2 ultimate RCV 934/5 joint Non-plunging $1800
Custom inner axles with 934 flanges $950.
3 cut-to-length 35 spline axle bars. $345
(this would work with the Spicer Ultimate CV axles outer stubs, as they have a 35 spline CV and axle bar.)

I'm using an upgraded knuckle and 1 Ton unit bearing that accepts 35 spline axles stub shaft... So the D60 stubs were an additional $850 each from RCV.

 

[Felix808]

Captain says we need more steam!

 

[BigMeatsBronco]

A little more progress here, the axle shaft bearings FINALLY arrived! Now I can send it back to the machine shop to get The case machined for the new axle bearings. Stoked! after it comes back next week I can send it off for gears and Locker install. need that done before I can get critical measurements for the inner axle bids.

 

[Snacktime]

Its not to late to put small tires back on!

 

[BigMeatsBronco]

Well the beefy 74weld steering rack is still in the way, even after heavy modifications to the diff cover and the crossmember. A OEM 2.0 or 3.0 would help some, but as much as I would love to say to others that there is a simple way to do this swap, The reality is that a NEW case needs molded and cast with the pinion oiling in a different location for it to be a "easy swap" ... There is room if a new Casting was made!

I've resorted to more modifications than the normal D60 buyer/installer would likely be willing to do. Also, I'm doing an engine swap soon and don't want to build mounts for the 60FDU and then re do everything again for the new engine. So I'm taking my time to get it to fit with 2.7 while planning ahead for the 5.2.

It still needs to be positioned 1" forward more and 3/4" higher in the chassis to fit perfect. The steering rack and engine mounts are the hold ups, (while keeping clearance away from the plastic oil pan)
So I'll be moving the steering rack FORWARD 1.5".
This will require cutting and fabrication.

The rack (and the 60FDU) being moved forward will also help the engine swap I'm doing soon. So this is a move in the right direction for me.

 

[popo_patty]

Well the beefy 74weld steering rack is still in the way, even after heavy modifications to the diff cover and the crossmember. A OEM 2.0 or 3.0 would help some, but as much as I would love to say to others that there is a simple way to do this swap, The reality is that a NEW case needs molded and cast with the pinion oiling in a different location for it to be a "easy swap" ... There is room if a new Casting was made!

I've resorted to more modifications than the normal D60 buyer/installer would likely be willing to do. Also, I'm doing an engine swap soon and don't want to build mounts for the 60FDU and then re do everything again for the new engine. So I'm taking my time to get it to fit with 2.7 while planning ahead for the 5.2.

It still needs to be positioned 1" forward more and 3/4" higher in the chassis to fit perfect. The steering rack and engine mounts are the hold ups, (while keeping clearance away from the plastic oil pan)
So I'll be moving the steering rack FORWARD 1.5".
This will require cutting and fabrication.

The rack (and the 60FDU) being moved forward will also help the engine swap I'm doing soon. So this is a move in the right direction for me.

So time for a D50 TTB swap then!?

 

[BigMeatsBronco]

So time for a D50 TTB swap then!?

I've considered the center section from a older ford with TTB 50, but supposedly the cover is the same as a HP60? so It depends on how the Casting was made...also no 35 spline E locker options without custom work.

the advantage fit-wise is the 9" gear would have 1/2 less radius which would squeeze past the rack perfectly with a thin cover.

 

[BigMeatsBronco]

That's the appropriate size for 40s! Much better for some margin of strength. The Spicer FDU is probably a solid option for 37s. Nice work!

Spicers Ultimate FDU and CVs are good to 40" for sure! I had zero issues untill stuffed the 41s on it.

 

[BigMeatsBronco]

Well the CV flanges arrived. Getting closer.
Still waiting on 935 joints from RCV and the Dana 60 stub shafts from RCV as well. Those guys are so slow they are backed up and then backed up upon backed up. How could they be a CV manufacturer and only have one part in stock?

Of course the female side doesn't have the cutouts for high angle so I'll have to have the Machine Shop do some more work on that one. At least I was able to find off the shelf parts for these and saved a ton of money versus custom pieces.

Additionally, the two part use different bolts....12mm vs 1/2". So I may use a fortin 935 on the 1/2" side. they advertise their 935 non-plunging joint will operate up to 49° !!!


Pics are compared to the 32 spline spicer ultimate CVs.
The 35 spline shaft is obviously a cut-to-length design.

 

[mattusmc]

I wonder if this would have been a better fit…. obviously it wouldn’t be cheap all said and done, but space may be a little better https://www.spidertrax.com/IFS-4130-Narrow-Width-Housing

 

[BigMeatsBronco]

I wonder if this would have been a better fit…. obviously it wouldn’t be cheap all said and done, but space may be a little better https://www.spidertrax.com/IFS-4130-Narrow-Width-Housing

I've looked at those, It's possible with oil pan mods. but the 9" actually has less clearance around critical areas, the 60 casting follows the contour of the ring gear and diff...the Ford 3rd member is limited by the big circular flange that basically wraps around the whole dropout.

 

[paradisepwoffrd]

Any updates?

 

[BigMeatsBronco]

Kinda, the 5.38 HP60 arrived, and CV pinion yoke, waiting on the E-locker...
Ill give a real update in 2 weeks (KOH spectating is the priority right now).

May also need to modify my new oil pan on the 5.2 engine.

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