Jake Downs wanted a narrowed Dana 60 for his early Bronco. He got this; and more. During the build-up process, while we were trying to figure out the best way to make the weld on wedges that normally come on a stock 2 3/4" tube fit on the Dana 60's 3 1/8” tubes, we came across a unique solution. A lot of grinding is usually the answer but having an extra Dana 44 front end from a 78 bronco that had a damaged center section led to an excellent way of allowing the front end to articulate. By boring out the cast wedges to fit the Dana 60 tube we were able to slip them on prior to installing the knuckles. Welding one in place to handle the torque, we were able to allow the other one to rotate while the suspension articulates. A lock bolt will be installed to hold the wedge in place for on road stability.

First, the plug welds were removed and the tubes pressed out of the housing. The axle tubes had to be switched side to side because the Dana 60 front end came from a Chevy and the center section was on the wrong side to work with the Ford T-case. Six inches were removed from the long side for a total track width of 62-inches and a 4340 35-spline axle shaft was made to match. The short side was kept the same length to made things easy so that an off the shelf axle would work on at least one side.

Next the hubs had to be modified as the Dana 60 was originally from a dually truck. The outer flange was machined off and the hub casting turned down to fit a standard 8 lug wheel. 5/8” drive studs were installed in the flange that the brake rotors originally bolted to. Now the rotors will bolt onto the back and the wheels onto the front. The brake rotor flange was welded onto the hub from the factory, and in order to provide a flat mount up for the wheel a 3/8" plate was placed on the flange with a 45-degree bevel on its backside to cover the weld.

We gave our customer only the best wedgies possible including a fully rotating one at that.

The 78 Bronco wedgies were bored to fit the Dana 60 tube then the one for the right side had a set of grease zerks installed to make sure there would be no galling during articulation. The rotating wedgie was held in place with a set of ¼” rings welded on each side of it to the tube. These above two pictures (2nd row) may look the same, but a quick check of the track rod bolt shows how this set up will rotate 360 degrees around the tube.

Here is the Beef. The wedgie for the left side was left loose on the housing so that the customer can fit it to his radius arms. After the pinion angle is placed at 11 degrees to line up with the t-case the caster will be at 6 degrees. Then the left wedgie will be welded in place in the vehicle to create the proper geometries. To complete the installation a stop bolt set up will be fabbed to lock the right wedgie in place for on road use.