35 spline Dana 60 conversion

The 35 spline axles are way to big to fit through the standard stub axles.
Some pics that will put it in perspective.
10 spline rover v 24 spline sals v 35 spline sals
https://www.aulro.com/afvb/images/im...11/06/1412.jpg
https://www.aulro.com/afvb/images/im...011/04/841.jpg

Hub bored out for bigger bearings
https://www.aulro.com/afvb/images/im...011/04/842.jpg

Stub axle difference, i went from older wide bearing spacing hub/stub
https://www.aulro.com/afvb/images/im...011/04/843.jpg
https://www.aulro.com/afvb/images/im...011/04/844.jpg
https://www.aulro.com/afvb/images/im...011/04/845.jpg

I highly doubt you could use the stubs from ebay, you need correct diameter for both bearings, correct bearing spacing, it needs same bolt pattern, same length, and it has a lip that tightly fits over the end of the sals housing...

Another pic, shows a d60 v sal ARB locker, the d60 looks way stronger, the cross shafts are alot larger.
https://www.aulro.com/afvb/images/im...011/04/840.jpg

Well the stub off ebay is for a 35spline Dana 60. So internals should be the same. Was more worried about length, the pcd and the width. Of course this will also mean bigger bearings etc. And machining of my d1 hubs, and that is fine. Do you have any measurements of you rovertracks stubs?

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Originally Posted by klappers

Well the stub off ebay is for a 35spline Dana 60. So internals should be the same. Was more worried about length, the pcd and the width. Of course this will also mean bigger bearings etc. And machining of my d1 hubs, and that is fine. Do you have any measurements of you rovertracks stubs?

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Unless you are a fitter and turner or have a best mate who is, then trying to use Dana stub axles and rover hubs will be a world of pain and/or $$$$$.

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Originally Posted by isuzurover

Unless you are a fitter and turner or have a best mate who is, then trying to use Dana stub axles and rover hubs will be a world of pain and/or $$$$$.

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I do... I have access to a man with a wealth of knowledge with regards to machining and he does have a lathe....


You still need a bigger hub for the 35splines anyway ie. machine the guts out. I was just thinking in terms of ease of use and parts...

Hmm after more reading and searching, 30 spline may well be the go for me... After Cal posting up those pics of the 35spline axles.. I really dont think that I need something that HUGE!!!! How much easier is a 30 spline coversion... If I can still use my original stubs... does this make it a much easier swap? 30spline axles and then 30 spline locker??

Canned the idea of those dana 60 hubs!!! Silly me. Sorry people ;). I didnt look at the spindle close enough. It would appear that there is a step on the spindle!! Lol

IIRC 30 spline can use the original stubs slightly bored out? its been a while since i was looking at options,, best bet is to email Keith from rover tracks, hey can sort you out no mater which way you go, he can also sort you out with d60 gear sets if you decide to go that way, cheaper then the KAM option.

Quote:

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Originally Posted by cal415

IIRC 30 spline can use the original stubs slightly bored out? its been a while since i was looking at options,, best bet is to email Keith from rover tracks, hey can sort you out no mater which way you go, he can also sort you out with d60 gear sets if you decide to go that way, cheaper then the KAM option.

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By a mile!!!

I was only going to go KAM gears on the front and then run a stock 4.1 D60 ratio for the Salisbury.. :)

What I was thinking of to start with was to do a ratio change on the salisbury while it is out of the car. Then source some 4.1 KAM front gears and put both in at the same time.

Then run this set up for a while and then drop in a 30spline lockright in the salisbury and 30spline to diff and convert to discs at the same time :)

Well just got an email back from Keith at Rovertracks!! Awesome response! Only emailed him a couple of hours ago. Seems that after all of that, that the 35spline is still the way to go.. So, 35 spline we go :)