DANA 60 Swap who's done it?

[cpmont]

Low mileage 1997 Mountaineer with 4x4 Swap: I have a DANA 30 (not installed) and am getting ready to start the install. The swap is a lot of work and I don't want an undersized axle that leaves me underwhelmed. I have started considering a DANA 60 swap front and rear from F350. Couldn't find a thread so asking here. 4x4 shop told me to stick with the 30 as it can handle 37s just fine, but I'm not convinced. I plan on over landing 1000 plus mile runs in the Mountaineer when its done. Also considering a transmission upgrade. Could just buy 4runner like everybody, else but I like my Mounty. Why blow 40-50g's for a new rig when I can upgrade mine for less than 10? Looking for ideas.

 

[Mbrooks420]

If you have a V8 you shouldn’t need a transmission upgrade, they are plenty stout. I’m pretty sure members here have done both D44 and D60 swaps.

Whether or not the D30 holds up will depend on your driving style. If you like to use the skinny pedal to just plow and power through stuff than the D30 combined with much larger tires probably isn’t the best option.

 

[Mbrooks420]

SVO42's 1-ton SAS

D60 install.

Solid Axle Swap Registry

List of other SAS’d registries.

 

[cpmont]

If you have a V8 you shouldn’t need a transmission upgrade, they are plenty stout. I’m pretty sure members here have done both D44 and D60 swaps.

Whether or not the D30 holds up will depend on your driving style. If you like to use the skinny pedal to just plow and power through stuff than the D30 combined with much larger tires probably isn’t the best option.

Will not be rock crawling, mainly maintained roads and trails.

 

[2TimingTom]

You’re not rock crawling and want to garage-engineer a suspension/steering system? If that’s all you’re doing then I’d leave the IFS.

I have a Dana 30. I’d only go 35s max. But if all you’re doing is fire roads and maintained trails, 37s will be massively overkill.

 

[Rick]

4x4 shop told me to stick with the 30 as it can handle 37s just fine,

They are used to putting 37s on light weight Jeeps, not on a heavy Mountaineer. Without upgraded axle shafts and u-joints 37s will break stuff in a D30. I broke stock D44 parts while running 36s. Once I upgraded to the CTM U-joints and chromoly axles I didn't have any more issues.

 

[imp]

Low mileage 1997 Mountaineer with 4x4 Swap: I have a DANA 30 (not installed) and am getting ready to start the install. The swap is a lot of work and I don't want an undersized axle that leaves me underwhelmed. I have started considering a DANA 60 swap front and rear from F350. Couldn't find a thread so asking here. 4x4 shop told me to stick with the 30 as it can handle 37s just fine, but I'm not convinced. I plan on over landing 1000 plus mile runs in the Mountaineer when its done. Also considering a transmission upgrade. Could just buy 4runner like everybody, else but I like my Mounty. Why blow 40-50g's for a new rig when I can upgrade mine for less than 10? Looking for ideas.

@cpmont
A very basic problem exists with doing what you suggest: An F-350 front axle will have a much-different steering geometry due to it's different wheelbase. This comes from the "Ackerman Principle" which dictates that lines drawn through the front and rear axles must meet in a point when the front wheels are steered. It's brought about through something called "king-pin inclination", though no king-pins exist. The axis about which the front steering knuckle pivots is tilted inwards as well as backwards, which causes "caster angle". imp