Custom 5x5.5 Full-Float Dana 60 AxlePosted in How To: Transmission Drivetrain on May 1, 2011
Early Fords, Jeeps, and Suzuki 4x4s often came with 5-on-5 1/2 bolt pattern axles. They weren't always the strongest tire spinners. In the realm of rear axles, Ford's 9-inchers aren't bad, Jeep's two-piece axles aren't great, and Suzuki's little Samurai axles are, well, little. Don't get us wrong; these axles all hold up fine when it comes to spinning stock size tires, but add deep gearing, bigger motors, heavy rubber, and an American work boot wrapped around an adrenalin-junky driver's right foot, and things can get messy.
You can upgrade axles completely, or just upgrade the axleshafts to stronger alloys. Or you can upgrade to full-floater hubs and alloy axleshafts from Solid Axle and Spidertrax, the option we like. We started with a junkyard Dana 60 housing and built it into an overkill idiot-proof bash axle that'll laugh off whatever the numbskull behind the wheel throws at it.
This project is a good mid- to high-skilled endeavor, requiring precision machining and welding, so if your barn has a lathe and a MIG machine you're in business, if not, you may want to take it to a professional.
|STRONG? YES. CHEAP? NO.|
|Solid axle||Full-floater kit||$1,120|
|Solid axle||Drive flanges||200|
|Yukon Gear||Gears & install kit||365|
|*Plus the cost of a junkyard housing and|
|labor to machine, weld, and set up gears|