Dana 44 vs Dana 60: Differences and Which Is Stronger
If you are shopping for gears, a locker or axle shafts, or planning a solid-axle swap, you need to know whether you are dealing with a Dana 44 or a Dana 60. The two axles look alike from a distance. Inside, the Dana 60 is a heavier-duty unit in almost every dimension that matters. This guide lays out the published differences, how to tell which one is under your truck or Jeep, and which one makes sense for your tires, weight and horsepower.
Quick Answer: Which Is Stronger?
The Dana 60 is stronger. It has a bigger ring gear, a bigger pinion, thicker axle tubes, larger axle shafts and larger U-joints. OffroadXtreme sums it up this way: "The Dana 60 has a larger ring gear, larger axle tubes, larger axle shafts, and overall is much stronger." The cost of that strength is weight. A Dana 60 adds a lot of unsprung weight, which affects handling and ride.
Dana 44 vs Dana 60 Specifications Side by Side
| Spec | Dana 44 | Dana 60 |
|---|---|---|
| Ring gear diameter | 8.5 in (8.9 in upgraded version, used in the JK rear) | 9.75 in |
| Pinion shaft diameter | 1.375 in (most); 1.625 in (JK rear 8.9 in) | 1.625 in |
| Pinion spline | 26 spline (most post-1970); 24 spline (JK); 10 spline (early pre-1970) | 10 or 29 spline |
| Axle tube diameter | 2.5 to 3 in | 3.125 in |
| Axle shaft splines (OEM) | 10, 19, 29, 30, 32, 33, 35 | 16, 23, 30, 32, 35 |
| Gear ratio range | 2.72:1 to 5.89:1 | 3.31:1 to 7.17:1 |
| Carrier break | 2.72-3.73 / 3.92-5.89 | 3.31-4.10 / 4.56-7.17 |
| Front U-joint (snap ring to snap ring) | 2.18 in | 3 in |
| GAWR | Up to 3,500 lb | Up to 6,500 lb |
Sources: Dana 44 ring, pinion, spline, ratio, carrier-break and GAWR figures are from the Wikipedia Dana 44 entry; Dana 60 ring, pinion, tube, spline, ratio, carrier-break and GAWR figures are from DieselHub's Dana 60 page; tube and U-joint figures are from OffroadXtreme and Big Bear Engine Company.
One note on the pinion: the 8.9 in Dana 44 used in the JK Wrangler rear has a 1.625 in pinion, the same diameter as the Dana 60. The ring gear and shafts are still smaller than a 60's.
How to Tell a Dana 44 From a Dana 60
- Look for the cast number. Dana axles usually have "44" or "60" cast into the housing near the carrier. Clean the housing and check before you order anything.
- Measure the axle tube. A 3.125 in tube points to a Dana 60. A tube between 2.5 and 3 in is a Dana 44.
- Check the vehicle rating. Dana 60s were used under 3/4-ton and 1-ton trucks. DieselHub lists Ford 3/4 and 1-ton front axles from 1974-2011, Dodge Ram fronts from 1975-2002 and GM fronts from 1977-1991. Dana 44s were used under Jeeps and lighter trucks.
- Front knuckles. DieselHub notes that Dana 60 fronts used kingpin knuckles until 1991, when ball joints became standard.
- Check the ratio tag or count teeth. You need the ratio anyway to order gears or a carrier, because both axles have a carrier break (see below).
Why the Carrier Break Matters When You Order Parts
Both axles use two carrier sizes depending on gear ratio. On a Dana 60, ratios from 3.31 to 4.10 use one carrier and 4.56 to 7.17 use another. On a Dana 44 the split is 3.73 and numerically lower on one side, and 3.92 and higher on the other. If you go from 3.73 to 4.56 on a Dana 44, or from 4.10 to 4.88 on a Dana 60, you need a new carrier or locker as well as gears. That is why lockers such as the Detroit Truetrac are sold by ratio range as well as by spline count.
Which One Should You Run?
Stay with a Dana 44 if:
- The vehicle is a Jeep or half-ton on moderate tires and you want to keep weight down.
- You care about ride, handling and fuel economy more than maximum strength.
- You want low cost for the strength you get. Big Bear Engine Company calls the 44 "a very good cost to strength ratio" and notes it is easy to upgrade in the aftermarket.
Step up to a Dana 60 if:
- You run large tires with deep gears. The 60 goes up to 7.17:1 and the 44 stops at 5.89:1.
- The vehicle is heavy (3/4-ton, 1-ton, or a built rig with armor, winch and gear). A GAWR of up to 6,500 lb vs up to 3,500 lb is a big gap.
- You are adding a lot of torque, for example with a diesel swap, or rock crawling where shock loads break 44 shafts and U-joints.
The Fix: Upgrade Parts for Each Axle
Most people who search for "Dana 44 vs Dana 60" are either upgrading a 44 to survive bigger tires or re-gearing a 60 to suit them. The most common parts on both axles:
- Ring and pinion: Re-gear after going up in tire size. For a Dana 60, the Yukon Dana 60 4.56 ratio gear set is on the numerically higher side of the carrier break. For a Dana 44 rear, the Revolution Gear Dana 44 rear 3.73 ring and pinion set is on the lower side.
- Traction differential: A Detroit Truetrac is a gear-type limited slip that needs no clutch service. Match both spline count and ratio range. Options include the Eaton Detroit Truetrac for Dana 44 rear, 32 spline (913A582) and the Eaton Detroit Truetrac for Dana 60 rear, 35 spline, 4.56 and up (915A386).
- Axle shafts: Chromoly shafts are the usual upgrade for a Dana 44 front on bigger tires. See our axles and yokes collection.
Browse every carrier, locker and limited slip in our differentials collection, or gear sets in ring and pinion.
Replace While You Are In There
- Carrier and pinion bearings, plus races (a master install kit covers these)
- Pinion seal and crush sleeve, or a solid spacer
- Axle seals, and on fronts, inner tube seals
- Ring gear bolts (new, with thread locker)
- Diff cover gasket or RTV, and fresh gear oil to the axle's spec
- Front U-joints and ball joints on a front axle that is already apart
Cost and Effort
A re-gear on either axle is precision work. Setting pinion depth, backlash and bearing preload takes special tools (dial indicator, inch-pound torque wrench, setup bearings) and patience. A shop typically quotes several hours per axle, and a full front-and-rear re-gear with lockers is a day's work or more. A locker-only swap with the existing gears is less work but still means pulling the carrier and re-checking backlash. A complete Dana 60 swap is the biggest job, because axle width, spring perches, steering, driveshaft length and brakes all have to be sorted out. If the only thing you are breaking is shafts or U-joints, upgrading those parts on your current 44 is usually the cheaper route.
If you are working out what ratio to run, see our guide to 3.73 vs 4.10 gear ratios.
Frequently Asked Questions
Is a Dana 60 stronger than a Dana 44?
Yes. The Dana 60 has a 9.75 in ring gear vs 8.5 in on a standard Dana 44, a 1.625 in pinion, 3.125 in axle tubes, larger shafts and 3 in U-joints. Its GAWR goes up to 6,500 lb vs up to 3,500 lb for the Dana 44.
Can Dana 44 gears fit a Dana 60?
No. The ring gear diameter, pinion and carrier are all different sizes, so gears, carriers and lockers are specific to each axle. Order by axle model, spline count and ratio range.
What tire size needs a Dana 60?
There is no single cutoff. It depends on vehicle weight, torque and how hard you drive. The published limits give you a guide: the Dana 44 tops out at 5.89:1 gearing and a 3,500 lb GAWR. If you need deeper gears or more capacity than that, the Dana 60 is the better fit.