Anyone build their own Dana 60? How to id a good housing?

Budget for the Cuda got cut again, so now I have to figure out where to cut it from. Was going to order a Dana 60, But I can afford it. I was lucky enough to score for free a late 70’s ford Dana 60 3/4 ton rearend for free, so I think that might be the way to do. Though it says D60 on one of the diff corners, I know a few fords came with a Dana ‘61’ style rearend. I don’t know if that is the same or not as a Dana housing, but very little is available for that rear. So anybody exterior wise the difference from a 60/61 case, and how would you build it for an street/strip car?

my dad said if he remembers correctly, a dana 61 will have an approx 1-2" distance from the cover to the front. also he thinks the 61 takes a longer pinion. i will ask him if he has a pic.

61 they moved the pinion to accommodate like a 3.07 gear….. on your “free” rear determine the gear ratio. More than likely if the casting says “60” that’s what it is. Prob a 3.54 ratio.

Also check the axle tubes, some fords used a smaller tube than 3".

Some differences for sure between the two. ive done 3 8 3/4 to dana swaps I’ve bought ends and perches from dr diff. cut and welded the ends myself using a friends kit the first time. made My own and used on the other two. With new everything,ie. spool, begs axles( had the gear sets I was into it 800.00 us.

Is there a six-digit number stamped into one of the axle tubes which gives you that info?
I know the Dana 70 in my Ford flatbed was easily identified that way.

Speaking of which, has anyone built a D70 from a truck rear? It's an even bigger ring gear than the 60, and usually has a 4.10 or deeper...

Sox put one in his early pro stockers back in the 70s or 80s

I bought a Dana 70 out of John Deanna old duster, it had 6.87 gears in it.
I swap them out to a used set of 5.38 ratio out of a Ford truck Dana 70 that I had swap a set of 4.10 into for a friend. That truck was a 1960 one ton ramp truck that had a 3 speed over, direct and under drive auxiillary(SP?)also known as a Brownie in line tranny.

Didn't know folks were using the dana 70, though it was always the 60. good to know. So for a fairly heavy car (1970 CUDA, all steel, iron block, 10.5 tire), who makes a strong axle that would be good for it? Tru-Trac or a locker diff? I'm probably going to farm out the mechanicals as have the proper equipment.

35 spline street and strip axles with a good clutch type posi worked forever in street racing for many years for many racers running low 8s on the street back in the day.
My S/P car has Mark Williams 40 spline axles and spool

The factory style powerlock diff is really strong.

The one I built for my dad's road runner was probably the cheapest ever, lol. Bought the complete rear for $150 from under a '70s dodge truck IIRC. It came w/ a powerlock diff., good 3.54 gear, and surprisingly it had a 1350 yoke on it.
All I bought for it was new 35 spline axles, 35 spline side gear and rebuild kit for the diff., housing ends and perches...all from Dr. Diff. Good friend of mine narrowed it and welded it all up. Built it myself.

Did the same thing for the Dana under my other road runner. Craigslist Dana 60 from a '70s Ford truck (had a bad ring and pinion and the weaker tracklock diff.) for $125. Used 4.10 gear from moparts for $75, spool, axles, ends, 1350 yoke, and perches from Dr. Diff.

I built the one in my Avenger. Was a 1 ton rear. Been 1.12 sixty foot

Pretty much all e250 and e350 vans came with Dana 60’s. They are very common and cheap. They do have 3.5”x3/8” wall tubes though. I just finished one for my truck. It came with 4.09 years and then used dr. Diff housing ends and spool with strange 35 spline axles and the brakes off of the 8 3/4. It believe it weighed 62lbs. more than the 30 spline 8 3/4 with a spool.

Mine came out of an old F350 for $100. Local guy cut it down and welded on Moser ends for $150 and set the gears up for $100.

Sweet diff! Is that a moser cover? That looks THICC! That would be great for added strength. I just got off the phone with the only builder in my area and they don't fab work anymore, they just assemble now. Though If I can do all the mods myself or someone I know, they said they could assemble everything for $500 and I supply all the parts, which is cheap insurance since I've never built one before.

Skip the cover and buy aftermarket caps.

Fearless Gear in Fresno?

That’s steep to just set it up. $200 for me

I disagree
I would and have bought both the preload covers and 2 steel caps for both sides on a Dana 60 for high output(2500+ HP) use

found a dana 44 on HAMB page 40? not sure if this would work for same one.


City: YORK
State: Pennsylvania
Price: $200 OBO
Pulled out of a running 55 Ford Ranch Wagon

44's are not as strong as the 60's, but i don't know what size ring gear they have.
i think if one was thinking about using a 44, i would strongly consider a ford 8.8 from an explorer.
reasonably strong, close to usable width as is, and comes with factory disc brakes.
just my opinion. your mileage will vary.

We did one. Paid $65 for one out of a Dodge ton truck. Member farmboy cut the ends off of a spare 8 3/4 we had lying around, chucked them in the lathe. I had a local chassis shop weld them on and setup some factory 3.54 gears.

All told with new Dr. Diff axles and spool, I had ~$900 in it.

Those are all old parts from the early 1960s no longer support by the manufactures except the Dana 44 rear end.
They are not as near as strong as the Dana 60
They were used in many light duty applications including the front differential on many 1/2 ton 4X4 pickups, they do break with a little abuse

Most any old dodge Dana 60 out of a 72-93 3/4 ton truck will be good. Most had 4.10’s.

I have a Dana 60 HD with a set of 4.10’s and a sure grip unit that needs to be rebuilt (sure grip unit itself) for sale if your interested. The bare housing was stripped and painted with Nason Farm&Machine gloss black out of a spray gun. I was gonna use it in my power wagon.
I’m in Hollister.

Toby Lavender, Lavender Brothers in Salinas can build it for ya.