Dually 4x4 conversion

Imbecile

Member
I finally located a lower mileage 2006 Ford Dana 60 front axle. I had to drive nearly 450 miles to pick it up yesterday and bring it back home.
Its going underneath my 2005 E-350 superduty dually cutaway using the Timberline kit which i already have.

Since i was unable to find any specifications in regards to the Ford F-350 Dually dana 60 when i was trying to research online, here are some basic measurements i have taken so far today before my back started hurting and i had to call it quits for the day after unloading it. This unit is from a 2006 Ford F-350 dually.

Dually wheel adapter measures 4" inches from the rotor mounting surface to the wheel mounting surface.

The bearing hub lug pattern is 8x170mm, however the wheel lug pattern on the dually adapter is 8x200mm.

The rotor measures 4" inches from the back side of the rotor to the front mounting surface of the rotor.

The distance between the back side of one rotor to the other is 63.5 inches for a total overall width of 79.5" inches WMS to WMS, that includes the dually adapters.

Just a quick two second observation it appears the caliper and rotor combined measures about 15" inches across. Im hoping once i have custom dually adapters machined my current 16" inch ALCOA wheels will clear the brakes. I was expecting the caliper and rotor to be more in the neighborhood of 16" inches. But i will have to do some more measuring when im not so tired.

The axle is in really nice condition, even the paper stickers are still on the axle tubes, but it does have a few spots i might touch up with some paint.

Does anyone have suggestions as whats best for painting an axle? Something that will actually stick and not come off in three months?

If you guys were converting a dually cutaway to 4x4 would you try to retain your existing fancy smancy 16" Alcoa wheels by having new 8x6.5 dually adapters machined from forged steel or would you retain the 8x200mm pattern and run the larger 17" ford dually pickup wheels? If i keep the 8x200 pattern on the front that means i will have to pull one of the rear axle bearing hubs and send it to the machinest and have him build a pair of 8x200mm forged steel bearing hubs for the rear axle. I dont want to mess with trying to swap out the rear axle on this thing. Dually wheels for the Ford pickups are pretty limited selection in 17", even though they arent totally ugly, they arent near as nice looking as the Alcoas.

Regardless, i will still need to have new front dually adapters machined for it because they need to be right about 3" inches not 4". Also if i have rear bearing hubs machined for it to use the 8x200 pattern, they will have to move the wheel flange portion outward on the hub to compensate for the deeper ford pickup wheel offset/back spacing.

Alcoa makes a wheel for the F-350 dually, but the smallest diameter is 19.5" and i dont want that big of a wheel on my rig, plus a good 19.5" tire is over $400 each.

The 17" inch dually pickup wheels look like the ones in these pictures... The top picture is a dually with the Alcoa wheels.
There simply is not anything else available for them in 17" with 8x200mm other than standard steel wheels.
(There are a couple of aftermarket dually sets available, but the price makes them totally unreasonable as an option for me. After all its a 4x4 truck so the wheels will eventually get bumped and dinged eventually)

The more i look at the F-350 wheels the more they grow on me. Just not sure how they would look on a Van. What do you guys think? The picture in the middle obviously has Alcoa's just for comparison purposes.
 

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Imbecile

Member
Just a side note, if you ever plan on doing a 4x4 conversion using these 05+ dana 60 axles be prepared. The things literally weigh 600 pounds ( at least the dually version does) two grown men together could not lift the heaviest end together more than 1/4" inch off the ground for anything beyond 3 seconds.
 

broncobowsher

Adventurer
You might be able to take the dually adaptors off the front axle and send them out for machining to get the bolt pattern you want. Check with places like Dutchman axle.
 

Imbecile

Member
I already have a machinist fully capable of making anything i need to my specifications. It isnt cheap by any means, but i know it will be right the first time.
Here is some of their work..... Super singles are not an option for me, i dont trust them and this vehicle is tall. Theres a reason vehicles this tall use dual rear wheels.
Imagine having a rear blowout at 75 mph on the interstate on the drive axle with only one tire per side on the rear of a truck thats 10'6" tall. That extra tire and wheel give you the ability to get the vehicle stopped before you lose control and flip the truck. Semi trucks can get away with super singles because they have two axles, even the trailer has two axles, that extra tire allows them to get stopped without flipping the truck. I would never put super singles on a truck i own.

Not to mention the fact if i have to replace a tire while traveling i can get a tire at most any tire shop and it will be on the shelf versus having to spend two days trying to locate a super single. Super singles make zero practical sense on a vehicle that gets used with any frequency.
 

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Joe917

Explorer
Blow outs are not the reason semis have dual axle and wheels, it is load carrying capacity.
If you are close to your load capacity and you have a blow out on a dual wheel single axle the other tire will probably go with it.
I can get a new tire at almost ant truck shop anywhere.
Singles are far superior off road.
You have to go with what you are comfortable with, good luck.
 

Imbecile

Member
Please show me where i stated that semis have dual axles for blow out reasons. Semis existed long before super singles were ever a thing.
I clearly stated the reason semis can get away with running super singles is because they have two axles. What i did not state is that semis have dual axles
in case youre running super singles and one blows out. Now we know why you are running super singles.

Truck stops generally do not stock an aggressive tread all terrain style super single tire. Their business is focused on providing tires to over the road truck drivers
not offroad enthusiasts.
 

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