dana 60 axle swap problems

[radracer1]

Ok guys i started my swap yesterday. Started with the rear axle first, thinking it would be the easiest ha wrong... Has anyone that has done this allready ran across this? The dana 60 i have came out of a 96 2500 and its going under a 2001 1500. After installing the u bolts i noticed on side didnt look right allmost if the axle purches was to narrow. So i unbolted everything and measured the d60 from center to center of the purches and it was 43 1/2, and the 9 1/4 is 44 1/2 center to center. Am i missing something here?

[swirvin21]

2500/3500 rear springs are 3" wide, 1500s are 2.5" wide. So you need to cut off the perches and reweld new 2.5" wide perches on, hence the differences in width. That is your only option, unless you want to swap to 3" wide springs, which is more work since you would need new conversion shackles and front hangars at minimum. Easiest and cheapest is to buy a set of perches and be done.

[jeff351]

I put a dana70 under my Ram 1500...same thing, the springs are different width. Like Swirvin21 said, just get the perches. Here is what I have... Spring Perches
(just make sure you order for correct axle diameter)

Torch off the old perches, grind the area smooth, mock up the new perches to correct dimensions and pinion angle, weld, and be done with it.

[The Dude]

I ran into the same problem. A few guys on here, me included, have ground down the corners of the perches so the u bolts fit and bored out the center holes on the existing perches. Obviously not the best method, but it worked for me and others in a pinch to get it together.

I was planning on welding new perches in, but I threw mine on the alignment rack and the thrust angle and tracking was perfect, so I figured why mess with it.

I also remember a guy, (i forget who) using ratchet straps and pulling the leafs closer and then bolting it together on his build page. This would probably mess up the spring bushings but that was another temporary fix to get it rolling.

The best way is new perches like already said but there are ways to make it work in a pinch.

[swirvin21]

There are many who have spent extra time, money and frustration making them work as it is, but considering that new u-bolts and perches are about $50 total it's just not worth it. Changing out bushings, grinding slots for u-bolts and anything else you can come up with to avoid new perches just isn't worth $50. Nice thing is with putting new ones on is you can fine tune your pinion angle without spending money on shims, the new perches have multiple spring pin holes to adjust wheelbase and they are typically longer than stock which decreases axle wrap....all this can be yours for $50

[boogerboss]

Just bolt them on, get them as flush as possible and bolt them on.

I didn't do any grinding, cutting, etc. I used new u-bolts with chevy u-bolt plates with the stock springs and block. No problems after 1.5 years and 6000 miles.

its an 01 1500 sport package and I used a Dana 70 from a 97 V10 truck

[RamSport59]

Ratchet strap them in and be done with it. Your talking. 5" difference. It won't hurt it.

Rick

[Wh1t3Nukle]

(02-03-2012 09:16 AM)swirvin21 Wrote:  2500/3500 rear springs are 3" wide, 1500s are 2.5" wide. So you need to cut off the perches and reweld new 2.5" wide perches on, hence the differences in width. That is your only option, unless you want to swap to 3" wide springs, which is more work since you would need new conversion shackles and front hangars at minimum. Easiest and cheapest is to buy a set of perches and be done.

(02-03-2012 07:23 PM)jeff351 Wrote:  I put a dana70 under my Ram 1500...same thing, the springs are different width. Like Swirvin21 said, just get the perches. Here is what I have... Spring Perches
(just make sure you order for correct axle diameter)

Torch off the old perches, grind the area smooth, mock up the new perches to correct dimensions and pinion angle, weld, and be done with it.

This is what I am planning to do as well, for the same reasons stated.

Slightly different question though, but related, in that let's say swap a Dana 80 under a 1500 with it's 2.5" width leafy springs. Anyone think there might be a weight issue of the boat anchor and these springs? Honestly I don't know the weight difference b/t the 70 and 80, but thought to broach this anyways.

Thanks

[hooligan]

if you've got the whole doner truck available, can't you switch springs, hangers and all?

yes, the rivets are a pain in the [censored], but free is free if you've already got the stuff laying around.

[radracer1]

Well got her done!!!! Man it was a pain in the a@#... lol.. For anyone going to do this swap all i can say is get ALL your parts before starting... LOL. Lets start with the rear axle. First plan on cutting the purches off and moving them both out a 1/2" on both sides. the dana 60 is 43 1/2" from center to center were the 1/2 ton is 44 1/2" center to center. E brake cables plan on getting them from the doner truck, need to cut the rear drive shaft around a 1" i did mine 1 1/4" and welded a new yoke tube for the 3/4 ton u joint. I got the yoke tube from a local shop for around 30.00. If you are using a older rear axle 94-97 on a 98-01 truck you will need to cut the abs wire from the doner truck and splice it into the ABS wiring harness Dodge changed to plugs in 98.

Front axle again if using a axle out of a earlier model you will need this parts, The sway bar, front brake lines right and left. I know on my 01 they used the dual piston brake cal which have a smaller banjo bolt size so i had to used brake lines off a earlier model truck. front u joint. i use two joints and made one that worked. I have the part numbers if needed. Good luck with your swap..