Brake issues Dana 60

[2005F250]

I put a Dana 60 in my 95 but I'm having issues with the brakes. The axle came from a 89 F350 Kingpin and there is one brake line coming off the frame to the caliper and on the 95 there are two lines giong into one but only on the drivers side. Anyone have any ideas on what I could do? I already tried swapping the lines but it didn't work.

[rusty1161]

If your problem is where the banjo fitting fits on the caliper, you can modify your stock line by filing down the ridge that creates the interferance. If you don't want to do that, contact Cary Towery at www.ctperformanceinc.com and he can supply semi custom stainless flex brakeline sets that will solve your problem. I went with his lines on my 1989 Dana 60 swap into my 1997 F250 because my lines were 13 years old and they are made for a 4" lift so they will work with a future 3" RSK/SD V code spring swap.

Good luck.

Rusty

[2005F250]

Actually I did think of filing but didn't want to do something I couldn't undo. I have been in contact with Cary the past few weeks about the swap and conctacted him after I posted this post and I'm gonna give him a call tomorrow. He's got a bunch of ideas. I have some questions for ya Rusty. I swapped a 89 in my 95 and everything went well besides the brake line issue but one thing that didn't work for me was the passanger side bolt on the tracbar bracket. It was to long and would hit the oil pan. Another thing was I couldn't get the bolts on the top of the cross member out that hold the TTB brackets they hit the oil pan and I just left them. On my frame I don't have factory hole for the F350 sway bar nor did I even have a sway bar on the TTB but I'm gonna run without a SB and see how it turns out. Did you run into these issues as well? I haven't installed the driveshaft yet, is there anything I should watch out for there? I just bought a complete F350 so I have all the parts plus some extra ones.

[rusty1161]

I had the same issues. I had to run some stacked washers to space the bolt out so it wouldn't hit the oil pan. And I ended up cutting out the bolts that held the TTB brackets on. I am not running a swaybar so I don't know about the holes for the brackets. I am still running the factory F250 driveshaft, but haven't driven the truck in 4wd. I have driven it with the hubs unlocked and in 4hi to see how it drives, no vibrations. I want to find some dirt roads to try out the true 4wd. I also have an F350 CV joint driveshaft and yoke I want to rebuild and install eventually, too.

Let me know if you have any more questions. This is a very worthwile swap for me, I hope it is for you, too.

Rusty

[2005F250]

It is a very worth while swap. Have had the truck 3 weeks and did this before I fixed the oil leak. No more twisting front suspension and no more broken beam hangers held in by 1 bolt. I think for the tracbar bracket I'm gonna put a stud in it and nut each side.

[desertwheeler]

IIRC when i did the swap on my 97 i got some Skyjacker brakelines for a lift and ground down the blocks so they fit right. I think they were just a line with 2 female ends and a brass block. ANd for the line on the drivers side i went to a local industrial supply store here and they made me up a line that made everything work together. I dont have pics of it anywhere but it was a short line that adapted everything to work. And i dont remember if it used the block or not either. I will see if i can dig up some old pics of it.