Ford has used the Dana 60 considerably since 1955, and continues to use it in some HD applications. The Ford Dana 60 has a driver side drop and reverse cut gears. Front axles used kingpin steering knuckles until 1991, when ball joints became standard. Most Ford Dana 60s and all 2005+ Dana 60s have 35 spline axle shafts. Dodge used the Dana 60 until 2002, as the 3rd Gen (2003-2007) Dodge Ram used AAM axles. Early Chrysler Dana 60s used a passenger side drop, standard rotation gears, kingpin knuckles, and 35 spline axle shafts. Later models used ball joints, a driver side drop, reverse cut gears, and 32 spline axles (though the 2000 - 2002 models retained 35 spline axle shafts). Ford and GM have always used standard locking hubs with their Dana 60 front axles, while Dodge used hubs until 1994, when they switched to a CAD (center axle disconnect) system (some 2002 model Dodge Rams are an exception and in fact had locking hubs).
The Dana 60 is praised for its brute strength and full floating configuration, with the kingpin front axle being the "Crown Jewel" for off-road rigs. At 500 lbs, its biggest weakness is its sheer weight. All early 60s were made of gray cast iron, while late models have been produced from ductile cast iron (the cut-off date is unknown). Dana suggests that the factory axle is rated for a maximum 38 inch tall tire. A semi-floating version of the Dana 60 exists, but is extremely rare - its GAWR is 5,500 lbs. A stronger variation of the Dana 60, called the Dana "Super 60", was used in the Ford F-450 from 2005 to 2012. It had larger 3.75 inch, 0.50 inch wall thickness axle tubes, a larger ring gear, thicker pinion shaft, bigger universal joints, and 35 spline axle shafts.
Dana 60 Specs
| Years Produced | 1955 - current | |
| Applications | Ford | • 1974 - 2011 3/4 and 1 ton, front • 1955 - 1998 3/4 and 1 ton, rear |
| GM | • 1977 - 1991 front • 1975 - 1987 1 ton pickups, rear • 1964 - 1977 3/4 ton pickups, rear • 1979 - 2012 1 ton vans, rear • 2002 - 2005 "Quadrasteer" rear |
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| Dodge | • 1975 - 2002 front • 1963 - 1993 Ram pickups, rear • 1994 - 2002 Ram pickups, gas only, rear |
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| Jeep | • 1968 - 1973 J3800/4800 • 1968 - 1970 J2600/2700/3600/3700 • 1971 - 1973 J400/4600/4700 • 1974 - 1988 J20 |
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| Full/Semi Float | Full floating front/rear differential | |
| GAWR | up to 6,500 lbs | |
| Overall Width | 69.339 inches flange to flange | |
| Ring Gear | 9.75 inches | |
| Axle Spline Count | 16, 23, 30, 32, 35 spline (35 most common) | |
| Axle Diameter | • 1.41 inches, 32 spline front axle • 1.50 inches, 35 spline front axle • 1.46 inches, 32 spline rear axle • 1.50 inches, 35 spline rear axle |
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| Axle Tube Diameter | • 3.125 inches, 0.313" wall thickness rear axle • 3.125 inches, 0.50" wall thickness front axle |
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| Pinion Spline Count | 10 or 29 | |
| Pinion Diameter | 1.625 inches | |
| U Joints | 1480 front universal joints | |
| Ratios | 3.31 - 7.17:1 | |
| Carrier Break | 3.31 - 4.10 | 4.56 - 7.17 | |
| Identification |  |
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