After debating whether to replace ujoints in my d44 front axle in my 2001 Ram 1500 4wd, I instead installed a d60 from a 94 Ram 2500 v10/5spd. Later year d60s apparently are more of a direct bolt in.

A few key differences I noticed:

• The upper control arm bolt holes on the axle are much smaller on the d60 vs the d44. I drilled them out to use the larger bolts from the d44. I am using the control arms from the 1500, the eyelets are larger on the front.

• Driveshaft-to-axle ujoint is smaller from the d44 vs d60; not a direct bolt-in. I should have grabbed the 2500s driveshaft while I was at the junkyard but didnt think of it at the time. Taking it to local shop (carolina driveline) to have them modify it for the correct-size ujoint for the d60.

• CAD is the same between the two.

• Front sway bar is the same diameter, but the ends are different between the two.

• Steering stabilizer on the 1500 drag link has no place to bolt to the d60. Not running a stabilizer for now. The 1500 drag link was way too long, the 2500 was too short, so I swapped tie rod ends and its about right for now. (Im only driving it locally for errands, it runs straight with just an eye-ball alignment.

• Coil springs are the same diameter. I am running the 1500's springs for now, just to keep ride-height the same. Lift kit is planned for later this year.

• Reassembled all the parts with plenty of antiseize. Installed new ujoints, axle seals, wheel bearings, rotors, calipers, brake hose, and new front brake lines (my lines were rusty to the point of being a safety concern)

Gear ratio doesnt match, so thats going to be Part 2 later this year, and then i'll install the front driveshaft.
Total cost for the axle and rebuild came out to around $1200. (The axle cost $650 and came with wheels, coil springs, and the track/drag/sway bar.)

 

 

yeah lets see some pictures!

 

d60 after dragging it home..



'01 Ram 1500 sway bar on the left, '94 Ram 2500 on the right)


after a several hours of cleaning with various wirebrushes and a coat of paint...




end result!

 

Gonna swap the rear to match?

Lookin' pretty good.

 

yes, thats the plan. I havent researched my options yet. The Ram 2500 I got the front off had the rear axle still there....$600. I might get it later

 

Grab the driveshafts, and t-case as well, if you can.

 

and the springs and shackles.

 

oh yeah! Plan on taking off as much extra booty as possible.

tip: a cut-off wheel and a small portable generator makes removing stuck bolts MUCH faster

 

...after a long break away from the truck this year, the lift kit is ALMOST done. I bought a used Skyjacker kit off ebay for $300-ish. Blasted all the grunge off the arms and brackets and got it bolted up with new grade-8 hardware. Also installed a steering box stabilizer (serious PITA trying to install that along with a sway bar!)
Bought a new set of 16.5"x9.75" Pro Comp wheels and 4 brand new 37" Goodyear military tires since I'm kinda partial to the durability of those tires.
For clearance I added a 2" spacer on top of the springs. Total lift is 6". I might be extending the control arms by approx 1.5"-2" to gain some tire clearance but for now its ok for daily driving. Only parts I don't have yet is a track bar, (waiting on someone who is supposed to be selling me his Thuren) and shocks. And of course upon inspecting the joints in the front driveshaft, they are toast..once I confirm measurements its going to Carolina Driveline for a rebuild.

I took the sway bar off since there are some compatibility issues with the lift and both of the sway bars I have. Plan on cutting off the perches on the axle and welding on something to gain proper alignment with the end links.





new height after lift is on!