This may be one of the biggest understatements ever made on this site.

Eric

LMAO!!! I love that pic.

For the record. The rear end was just fine. C clips and all.
I dont know but in my experience, the dodge clunk usually is treated by greasing the slip spline on the driveshaft. There is a zerk fitting for that. Everytime mine would start the clunk id crawl under there and fill 'er up with some grease and it would stop.

 

If anyone has side-by-side pictures of Dana 60 30-spline shafts and 9.25" 30-spline shafts showing measurements and metal quality/hardening process facts that prove the 9.25's shaft strength over the 60's, I'd like to see them. Even though the D60 is a full-floating axle and the 9.25" is a semi-float with c-clips and possibly a necked-down section.

I also would like to see this. I stumbled on one a long time ago but I don't know where I found it and I can't Google it out again. I'm thinking it was one of the magazines that did a comparison of many popular axles. I have a couple Dana 60s I would like to compare to another as I think they are both a bit odd.

One thing to remember about the 9 1/4's axle shaft size is that axle has to support the weight of the vehicle since all the load is put on it. Whatever cargo weight, weight transfer in turns, etc is all loaded directly on the axle shafts. With a full floating rear axle, the weight is carried by the housing and all the shaft has to deal with is the torque of the engine driving the wheels. This can make a big difference in axle shaft strength. Again, I've never said the 9 1/4" is a weak axle, only that it has a few problems that unless kept in check can cause catastrophic failure.

 

I stumbled on one a long time ago but I don't know where I found it and I can't Google it out again.

I was looking for the same link Lanty, as I remember reading it or one similar to it as well. The one I read had a D60, 14BFF, Chrysler 9.25, and I think a Ford 9" comparison.

What Erin said about the 9.25 having larger axle shafts is true. However, you do make a valid point in that they have to support whole rear end of the vehicle and load due to semi-float design.

I was also sure at one time that I had read an article on a C-clip eliminator kit to make the 9.25 a full float. I can't find that article either. I will keep trying to find it though.

Here are some measurements I found (not mine and I make no claim to accuracy)

Dana 44 rear axle...
Ring gear diameter = 8.25"
Pinion shafts diameter = 1.375"
Axle shaft diameter and spline count = 1.31" / 30 spline

Dana 60 rear axle...
Ring gear diameter = 9.75"
Pinion shaft diameter = 1.625"
Axle shaft diameter and spline count = 1.31" / 30 spline or 1.5" / 35 spline

Chrysler 9.25 rear axle...
Ring gear diameter = 9.25"
pinion shaft diameter = 1.875"
Axle shaft diameter and spline count = 1.32" / 31 spline

Here is some other info from our very own RCC.
http://www.ramchargercentral.com/index.php?action=printpage;topic=121538.0

I have seen several mentions of DTS having offered c-clip eliminators for it. Not sure if they still do.

I will see what else I can dig up on the 9.25's

Eric

 

The only 9.25" i never heard/felt Clunk was the one in my '76 Ramcharger. I dunno, maybe the 40" Mudders absorbed the clunk and the exhaust drowned out the sound though All the other 9.25's produced the same Clunk when the truck was put in gear. Come to think of it, my uncle's 1500 ate a 9.25" a few years after he bought it. IIRC it locked up going down the road at 50, something to do with the pinion. Can't quite remember the exact cause though, it's been too many years.

LOL Chris!!! Ask Rory about the 9 1/4" that tried to kill me on the Schuylkill Expressway a few years back.

 

I was looking for the same link Lanty, as I remember reading it or one similar to it as well. The one I read had a D60, 14BFF, Chrysler 9.25, and I think a Ford 9" comparison.

I believe that article was in 4wheeler magazine in the summer of 05 I think. I think it also compared the dana 44. I think it had the torque capabilities of each axle and the maximum tire size for each.

 

LOL Chris!!! Ask Rory about the 9 1/4" that tried to kill me on the Schuylkill Expressway a few years back.

I had actually thought about that event while reading this topic, Pete. Pinion nut came loose if I remember correctly? Which in turn dropped the pinion gear into the diff and locked everything up?

 

I had actually thought about that event while reading this topic, Pete. Pinion nut came loose if I remember correctly? Which in turn dropped the pinion gear into the diff and locked everything up?

Yeah Eric, the evil black '79 Trailduster Prospector from Jersey which, coincidentally, I found out later on was built on Friday the 13th.

Actually, it was the only wounded serviceable Mopar I've ever owned that I couldn't get back to my garage under its own power. All the rest made it and some, more than once. LOL

 

had a 9.25 peel a pinion like an onion once... had the normal clunk... and howled like banshee for weeks before i figured it wasnt the transfer case whinin... but its been strong enough for what i want... only rollin 33x12.50's now... a friend of mine thats been wheelin it seems since he came off the tit says with half ton runnin gear under that heavy truck dont wanna roll more than a 35... when i inquired about guys runnin 40's or bigger on jeeps with the same axles he said a jeep ways about 2/3 give or take what ur truck does... so eventually i will upgrade to 60's... just as soon as i finish remodelin the wifes kitchen...

 

I bought the "magic" crush sleve at carquest.  Walked right in and asked em for it.  I know its magic cause my 3/4 inch impact wouldnt crush it,...so, I ended up using a 3/4" breaker bar and a 6 foot cheater bar,....and with the help of not one,..... but two!!! magical fairys I was able to reach the correct preload.  But seriously the one I bought from carquest was noticibly harder to crush.  No telling who makes it and how it ends up in the box.

I also find alot of spinning races on 9.25.

IMO, I like 9.25

 

So you don't know what torque it crushed at?  Did you use a torque wrench?

 

As far as I know its supposed to be at least as good as the Ford 9"/better than the shabby 12 bolt, although I would personally take a 9" ford for the sheer parts availability if I was hell bent on half ton bolt pattern.

Personally I got a rear 60 and some 8 lug outers for the front.

 

I myself (not a buddy) have run approx. 20K on my 94 dodge 1500 with 42 iroks.  The truck has been interstate driven, pulled trailers, and been moderately wheeled.... but respected and well maintained.  I have not had a single problem with the factory 9.25 that now has well over 200,000 total miles on it.  I have changed the fluid and brakes, but thats it.  The D44 up front is a different story.  I would say that in an all around competition a properly built 9.25 would give a D60 a run for its money....

 

I was looking for the same link Lanty, as I remember reading it or one similar to it as well. The one I read had a D60, 14BFF, Chrysler 9.25, and I think a Ford 9" comparison.

What Erin said about the 9.25 having larger axle shafts is true. However, you do make a valid point in that they have to support whole rear end of the vehicle and load due to semi-float design.

I was also sure at one time that I had read an article on a C-clip eliminator kit to make the 9.25 a full float. I can't find that article either. I will keep trying to find it though.

The c-clip eliminator does not make the axle a full floater,all it does, is retain the axle from the wheel end, not the differential end.

Here are some measurements I found (not mine and I make no claim to accuracy)
Here is some other info from our very own RCC.
http://www.ramchargercentral.com/index.php?action=printpage;topic=121538.0

I have seen several mentions of DTS having offered c-clip eliminators for it. Not sure if they still do.

I will see what else I can dig up on the 9.25's

Eric

No one brought up the 9-1/4 HD (8 lug version). Has bigger tubes, shafts, bearings, and brakes then the standard 9- 1/4, and is even rated the same as the D60. Was used in place of the D60, on many applications without any issues.

 

I didn't read all of the posts, but I personally ran a 9.25 with 37" boggers and a nitro'd small block. 5.13s and lincoln locked. I broke one axle shaft but I had slid sideways into a rock and flat-footed kinda at the same time, No other problems. I think people get WAY TOO caught up in 60's and 70's. Soon 33s wont be adviseable without rockwells. For what you are doing, I think you will be fine. I won't say you will never break shit. You are driving an older truck, right? Breaking shit comes with the territory.

 

my brothers truck has 35x12.5 and we never had any problem with the 9.25 or the dana44 , it even ran 38.5 boggers for a while but lack of gearing so went back to 35" wheeled on rocks , sand and mud

the only downside i see is the limited options for gears but you want to run 4.10 so thats no a problem for you , if you dont brake you dont have to worry about c-clips...

mexican dodge trucks came with 5lug d60 and we compared the axle shafts , the 9.25 were bigger and with the smaller ring gear you have more clearance ,for me its the strongest 5lug availible in stock form , the 9" has weak axle shafts and its very fragile in stock form you need moser axle shafts and a locker or spool to make it work

 

If you are staying 1/2 ton and not wheeling it hard, I like the 8-3/4 with some moser shafts to get it back to 5 on 5.5 and gain some strength.  If your not familiar with them, they are similar in design to the ford 9" and came in 1/2 tons (the ones I have seen in trucks have been behind 6 cyl, but there is a lot of them in muscle cars holding up to major h.p.)
This way you keep it all dodge and bolt in fi that is a factor.

If you are going to wheel it hard, a 60/70 is the only way to go for bolt in and if you want to do some fab work, there is not limit.

 

mexican dodge trucks came with 5lug d60 and we compared the axle shafts

Man, I would love to see some pictures of them.

 

Man, I would love to see some pictures of them.

of the complete axle or just the axleshaft ? i can get the d60 pictures from a friends rc but i dont think i can convince him to dissasemble it just to see the shafts haha

 

of the complete axle or just the axleshaft ? i can get the d60 pictures from a friends rc but i dont think i can convince him to dissasemble it just to see the shafts haha

As much as you can, the mythical 5 lug D60 has been bragged about on here for years, but no one has yet been able to post pictures.

 

As much as you can, the mythical 5 lug D60 has been bragged about on here for years, but no one has yet been able to post pictures.

I know where there's a 5 Lug D60 sitting... Laying on the floor behind a '70 Cuda that belongs to the guy i get my A-Body parts from Oh wait, you didn't mean the Muscle Car 60

but there is a lot of them in muscle cars holding up to major h.p.

Muscle Cars, Drag Cars, Tubbed "Street" Trucks, ect. All of em getting excessive use of the Skinny Pedal. The 8-3/4 is a strong rear, even in stock form. It's why it's highly sought after. Especially the desireable 489 "Chunk" with Sure Grip (Which i happen to have a few of)

 

Especially the desireable 489 "Chunk" with Sure Grip (Which i happen to have a few of)

I don't like that whole crush sleeve idea.

I don't know about the crush sleeve eliminating the clunk. My 8-3/4s clunk, the 9-1/4 doesn't so bad, and the 8-1/4 does noticeably enough. (but the driveshaft and trans should die before it does) The 489 has the worst clunk of anything.

I like the link, got a stupid 489 that needs one of those deals too.

It's a decent rear, but there's enough breakage in them that I wouldn't use one in anything but a 1/2 ton truck. And even then I don't think it's good enough to pay a premium for.

 

As much as you can, the mythical 5 lug D60 has been bragged about on here for years, but no one has yet been able to post pictures.

lol , it firts came optional ( dana44 rear was std equipment ) on the dodge "limited" package ( top of the line ,leather seats ac power everithing etc ) on pick ups and ramchargers on 1992 , and since 1993 stock on every ramcharger ( until 1996 and then the rambody ramcharger also ) and the ram from 1994 until 2001 came with it also in 2002 they started with the chrysler 9.25 .

ill try to post some pics soon.

 

I'll eat my hat...

 

I'll eat my hat...

really ?

well this truck has one ,i have to tell him to take some pics of under the truck so you can really see it

sorry if im hijacking the thread...

 

really ?

well this truck has one ,i have to tell him to take some pics of under the truck so you can really see it

sorry if im hijacking the thread...

Well, heck yea, we always want more pictures. Underneath, interior, engine, we like it all. Nice truck.