Front Dana 60/61 swap

[slick]

Just picked up a 1990 Cummins 4wd chassis. I think I will eventually put my Crewcab on that frame . For now I'm thinking I want to put the 60 under my truck for now. I really want the disc brake swap. I have the master and booster from my 93 donor. My big question is the steering. Am I crazy to think I can turn this front end with my original manual steering box? I know I have to move the shock mounts, but I have also read that with the right components the original steering will work?
Thanks

[712edf]

I had a 78 W200 club cab with a Dana 60 front. I converted it to manual steering using a box off of a 72 Dana 70F equipped W200. The box was made by TRW. They are scarce.

Tire width (contact patch area) has a lot to do with how much effort it takes to steer. I had stock tires/wheels. It worked fine.

I sold the truck to a member (Doug) of the PW forums. He may still have the manual steering box.

Bucky

[712edf]

I just reread your post. I forgot you're not talking 72-93 but Sweptline instead. What manual box to you have now?

Bucky

[slick]

Factory rebuilt one on my 63. 235-85-16 tires

[digdoug]

Slick,
I think if I were planning on swapping frames later, I would leave the axle where it is. It is way too much work to just gain disks.
The short steering arm on the 60 ramps your ratio up a lot when combined with the long arm on the sweptys steering box (even a W arm).This makes for about an added 1/3 extra steering effort. There isn't enough room to swing a longer steering arm that could be sourced from a ford axle.

Cheers
Doug

[slick]

Thanks Doug, I was hoping you would chime in. That sounds like solid advice. The follow up question in the future will be asking if I should stretch the Cummins frame or move everything to my Crewcab frame . I'm leaning towards grafting my 2 Cummins frames together..

[digdoug]

I think you need to talk to the master in Hubbard Ore. for the answer to your 2nd question.I think Powerwagoncrazy has done it both ways. I assume you will be using a 6bt?

[slick]

Yes 93 Cummins

[PowerMan]

Through a lot of trial and error with castor and drag link angle it can be done. I'm using a rebuilt manual Red Head steering box (for my 62 W100). At first, I adapted a drag link to use manual steering with the factory box on the Dana 60 front. Steering was tough (285/75r16 tires) and had a good amount of bumpsteer (due to drag link angle). I ended up integrating the stock style sensing valve into the drag link and adding a PSC hydraulic assist cylinder (1.5" bore x 8" stroke). It works very well but looking back, if I was starting over, a frame swap/graft would be considered.

[slick]

Thanks, as much as I want it under my truck now , I think I'll wait and do it right once ..

[Wildergarten]

I am contemplating a similar change to a Dana 60.

I plan to add power steering, which my wife will need. The kit from EZ St. (#6169PSK-400D) looks good in that it preserves the existing geometry of the Dana 44, puts the steering forces into the length of the frame, matches my steering shaft, and doesn’t interfere with the PTO shaft for the winch. I had toyed with the idea of a crossover, but not only is that way expensive, getting the Panhard rod correct to preclude twisting the frame seems a poor compromise when I’m not building a high-lift rock crawler with monster tires! I’m suspecting it would be rather unfriendly to a PTO shaft as well unless I lifted the truck, which I have no reason not to do here. Rollovers are the highest safety risk I face here. It is very steep.

Unfortunately, the Ch3vy Dana 60 has a very short top steering arm on it that may inhibit the turning radius to the left on the Dodge. It will definitely require power steering. The distance between the drive hole on the steering arm and the spring on the Dana 44 is much less than on the Dana 60. So I do have room for a longer steering arm. The arm may also be able to come straight out with from the top of the knuckle similar to the Dana 44 arm, as there is a bend in the drag link on the stock D44 setup I may not need because of the larger size of the knuckle on the Dana 60.

Does anybody make a steering arm for a Dana 60 on this truck that is not for a crossover? I am assuming it would have to be annealed 4140 to be drilled and heat treated. Alternatively, I do have access to a shop that can CNC punch and plasma-cut that stock in one operation (they’re awesome; if you wish I can offer the reference). It would then require only reaming the tapers, welding on the cap, and a heat treat. That way, I can lay it out in CAD and own the fit.

If I get a longer steering arm to preserve the same geometry as the existing Sweptline-Saginaw manual system, I do need to find that length to put it in the same location as my existing Dana 44 installation because of the wider Ch3vy stance so as to avoid binding the drag link, inducing bump steer, etc.? Would that length be measured from the spring to the center of the hole in the steering arm? I’d rather not have to make a longer Pitman arm to match! Cutting those splines won't be cheap.

I will also need to add shock mounts to the front of the axle, but the clearances there are very tight. I hear that you folks make those. So I do have a few additional questions about the narrower center-to-center distance on Dodge Springs as well as how to clamp in their narrower leaves on the passenger side atop the pumpkin.

[pismopowerwagon]

I am looking forward to see what you end up doing with this swap Slick, asking questions is a great way to start and .

I love my D60 swap with power assist.

[soopernaut]

I am looking forward to see what you end up doing with this swap Slick, asking questions is a great way to start and .

I love my D60 swap with power assist.

I think he abandoned this and sold the axle.

[pismopowerwagon]

I am looking forward to see what you end up doing with this swap Slick, asking questions is a great way to start and .

I love my D60 swap with power assist.

I think he abandoned this and sold the axle.

Thanks

[slick]

Yes I pulled the plug and sold the axle. My truck is my daily driver and use it for my side business. I couldn't keep it off the road to work out the bugs, so I pulled the axle and put the original axle back in. The plan was a different box and crossover steering, but obviously it didn't happen. Maybe one day.