What size is the Dana 60 front axle?
The Dana 60 front axle does not have a single universal size. It exists as a family of variants that differ in ring gear diameter, spline count, carrier design, and overall width depending on the vehicle make, model year, and aftermarket modifications. This article explains the typical sizes you’ll encounter and how to verify the exact specification on your axle.
What is the Dana 60 front axle?
The Dana 60 (often called the Spicer Model 60) is a heavy-duty solid-axle front suspension used in a range of trucks and heavy-duty applications. It comes in several configurations over the years, including variations in ring gear size, axle shafts, and axle tube dimensions. Because there isn’t a single production specification that covers every variant, “the size” of a Dana 60 front axle must be understood in context of the specific build and vehicle it came from.
Common configurations
Below is a concise overview of the key sizing aspects you’re likely to encounter. The list highlights typical characteristics, noting that exact values depend on the specific axle model and production era.
- Ring gear diameter: The most common factory front Dana 60 uses a 9.75-inch ring gear (about 247 mm). This size is widely associated with standard, non-aftermarket front 60s used in many full-size trucks.
- Alternative ring gear options: Some heavy-duty or aftermarket front Dana 60s use a larger ring gear, such as 10.5 inches (about 266 mm). These variants are less common in stock configurations but appear in performance-oriented builds.
- Axle shaft splines: Front Dana 60 shafts have varied over time. Older units typically used 30-spline shafts, while many newer or upgraded/aftermarket 60 fronts use 35-spline shafts for increased strength.
- Axle tube diameter: The outer diameter of the front axle tubes generally falls in roughly the mid-3-inch range, with variations by model and builder. Exact tube sizes depend on the specific housing design and year.
- Front width/track variations: The overall width (track) of a Dana 60 front axle varies by vehicle application and installation kit. Different vehicle models and wheel/bearing configurations yield different track widths and mounting spacing.
In practice, the “size” you need to know will depend on what you’re doing with the axle—rebuilding, upgrading, or swapping into a different vehicle. Always confirm the exact spec for your particular unit, especially if you plan to pair gears, upgrade shafts, or fit a different differential carrier.
How to identify your Dana 60 front axle
To determine the precise size and configuration of your Dana 60 front axle, use the following steps. This will help you avoid guessing and ensure compatibility with parts and upgrades.
- Check the axle tag or stamped markings: Many Dana 60 front axles have a model tag or stamping on the housing that lists the model number, gear ratio, and sometimes ring gear size and spline count.
- Measure ring gear diameter: If the tag is missing, you can measure the inside diameter of the ring gear or the carrier to estimate whether it is around 9.75 inches or larger (e.g., 10.5 inches).
- Count or verify axle shaft splines: Remove a wheel and hub to count the spline count on the axle shafts or read any accompanying documentation. 30-spline is common on older units, while 35-spline is common on many newer or upgraded assemblies.
- Identify the axle type: Determine whether the front uses a full-floating or semi-floating hub arrangement, as this affects maintenance and compatibility with wheels and hubs.
- Check width and mounting specifics: Measure the distance between mounting surfaces or refer to vehicle service documentation to confirm the exact track width and spring/width setup.
Knowledge of these details will help you source correct gears, shafts, or replacement parts and ensure a proper fit for upgrading or maintenance.
Why the size matters for maintenance and upgrades
Choosing the right Dana 60 front axle size is critical for reliability and performance. A mismatch in ring gear size or spline count can lead to improper gear engagement, bearing failure, or incompatible aftermarket upgrades. When planning changes—such as stronger shafts, upgrade carriers, or different gear ratios—start by identifying your exact D60 variant and then consult manufacturer specifications or experienced builders for compatible components.
Summary
There isn’t a single “Dana 60 front axle size.” The front Dana 60 exists in multiple variants that differ mainly in ring gear diameter (commonly 9.75 inches, with some larger 10.5-inch options), axle shaft splines (30-spline vs 35-spline), and overall width. To determine the exact size of your axle, locate the model tag, measure key components, or consult vehicle and axle documentation. Understanding these distinctions is essential for accurate maintenance, gear exchanges, and any upgrades.
What size is a Dana 60 gear?
9.75 inches
A Dana 60 (D60) Ring Ring gear measures 9.75 inches.
Is a Dana 60 a 1 ton axle?
Yes, a Dana 60 is considered a 1-ton axle, particularly when it is the front axle found in 1-ton trucks. However, a Dana 60 rear axle is typically rated as a 3/4-ton axle, and while the Dana 60 is a heavy-duty axle, the 1-ton designation is specific to its application in 1-ton trucks.
You can watch this video to learn more about the differences between 1-ton axles and other types: 1mJK Gear and GadgetsYouTube · Jul 12, 2024
- Front axles: The Dana 60 front axle is the most common 1-ton axle found in 1-ton trucks and is also very popular for swaps into other vehicles because of its strength.
- Rear axles: A Dana 60 rear axle is generally rated as a 3/4-ton axle.
- Heavy-duty components: The 1-ton Dana 60 features larger components than its 1/2-ton counterparts, including a larger ring and pinion, axle shafts, and a stronger housing, which makes it more durable for heavy loads and large tires.
- Usage: While Dana 60s were originally used in 1-ton trucks, they have become a popular upgrade for off-roading enthusiasts due to their strength and durability.
Are all Dana 60 front axles the same?
If there are 7 bolts, then you have a GMC/Chevy or Jeep Dana 60 axle. These axles are all exactly the same. If there are 4 bolts, then you have either a Dodge or Ford Dana 60 axle. These two axles are not identical.
What is the diameter of the Dana 60 front axle?
Axleshaft Size
A modern Dana 60 front axle comes stuffed with much stronger 1.5-inch-diameter, 35-spline axleshafts (center), which can safely handle 37-to-44-inch tires. Aggressive drivers can take their Dana 60 a step further with aftermarket 1.70-inch-diameter, 40-spline axleshafts (left).
