When it comes to upgrading your rig for off-roading, towing, or serious work, axle selection plays a crucial role. Two of the most recognized names in the axle world are the Dana 44 and Dana 60. While they might look similar at a glance, these axles differ significantly in strength, application, and structure. This guide will walk you through exactly how to tell the difference between a Dana 44 and a Dana 60, with tips on identification, performance considerations, and real-world use cases.
Before we dive into the visual and technical differences, it’s important to understand why identifying your axle correctly even matters. In the off-road and truck enthusiast community, axle swaps and modifications are extremely common. Many used vehicles on the market today—especially older Jeeps, pickups, or trail rigs—may have been upgraded or pieced together with components from different models. That means the axles you see under a vehicle might not be what came from the factory.
If you’re buying a secondhand vehicle or hunting for spare parts, knowing whether you’re dealing with a Dana 44 or a Dana 60 is critical. The wrong identification could lead to mismatched components, incorrect gearing, or even safety issues when towing or off-roading.
Quick Overview: Dana 44 and Dana 60
Dana 44 and Dana 60 axles are both made by Dana Spicer, and they’ve been installed in various vehicles from the factory, including Jeep Wranglers, Ford Super Duty trucks, Dodge Rams, and Chevy pickups.
Dana 44 is typically used in light trucks and SUVs. It strikes a balance between strength and weight and is common in vehicles designed for moderate off-roading and daily driving.
Dana 60 is a heavy-duty axle found in 3/4-ton and 1-ton trucks. It is built to handle serious loads, extreme off-road conditions, and high torque applications.
Despite their similarities, these axles are built for very different purposes. Accurately identifying them is essential whether you’re planning a build, swap, or repair.
How to Visually Identify a Dana 44 vs Dana 60
Accurately telling a Dana 44 from a Dana 60 requires inspecting several features. Below are the key components and dimensions to examine.
Axle Tube Diameter
One of the most obvious visual cues lies in the axle tubes. Dana 44 axles typically have axle tubes that measure between 2.5 to 2.75 inches in diameter. In contrast, Dana 60 axles feature beefier tubes—usually 3.125 inches or more in diameter.
This difference is easy to spot if you have a caliper or tape measure. The thicker tubes on the Dana 60 allow it to support more weight and torque, making it ideal for trucks that haul or tow heavy loads.
Differential Cover Shape
The shape and size of the differential (diff) cover is another giveaway.
- Dana 44 diff covers are generally oval-shaped and smaller.
- Dana 60 covers are larger, more squared off, and bulkier overall.
Center Section (Pumpkin) Size
Another visual difference is the size of the pumpkin. Dana 60 pumpkins are significantly larger than those on Dana 44s. This extra size allows for a larger ring gear—9.75 inches on the Dana 60 compared to 8.5 inches on the Dana 44.
Why does this matter? A larger ring gear translates to more torque-handling capability. So, if you see a larger center section bulging below the axle tubes, you’re likely looking at a Dana 60.
U-Joint and Axle Shaft Size
The universal joints (U-joints) and axle shafts also vary:
- Dana 44 uses smaller U-joints like the Spicer 297X or 760X, which are adequate for light to moderate duty.
- Dana 60 uses larger Spicer 1480 or 1550 U-joints, capable of withstanding much higher torque loads.
The axle shafts in the Dana 60 are also thicker and stronger, making them more resistant to breakage during rock crawling or high-load towing.
Bolt Pattern and Lug Count
Lug pattern is another common method for identifying axles:
- Dana 44 axles usually come with 5- or 6-lug hubs.
- Dana 60 axles almost always have 8-lug hubs.
However, it’s important to note that lug count alone isn’t foolproof. Some custom or modified Dana 44 axles may have been converted to 8-lug, and aftermarket wheels may obscure the original pattern.
Kingpin vs. Ball Joint Design
Dana 60 axles—especially older ones—often feature a kingpin knuckle design, while most Dana 44s use ball joints.
- Kingpins are stronger and preferred in heavy-duty off-road applications.
- Ball joints are easier to service and lighter, suitable for everyday driving and light off-road use.
In recent years, many modern Dana 60s have switched to ball joints as well, so this distinction is more relevant for vintage axles or specific builds.
Bottom Drain Plug
Dana 60 axles often include a bottom drain plug, while Dana 44s do not. This subtle detail helps confirm identity during inspection. When it comes to raw strength, the Dana 60 wins hands down. The larger ring gear, thicker axle shafts, and beefier construction make it ideal for:
- Heavy towing and hauling
- Rock crawling and off-road abuse
- V8 engine swaps and high-horsepower builds
Compatibility and Swapping Considerations
Knowing what each axle came stock in can help you track down the right parts:
- Dana 44s came in vehicles like Jeep Wranglers, Ford Broncos, Chevy Blazers, and some Dodge trucks.
- Dana 60s are found in 3/4- and 1-ton versions of Ford, Dodge, and GM trucks, especially those built in the 1980s to early 2000s.
- Spring perch width might need to be modified.
- Driveshaft angles could change.
- Steering components must be reconfigured.
- Brake lines and gear ratios need matching.
How to Identify in a Junkyard or Used Sale
If you’re hunting for axles in a junkyard or buying secondhand, follow this checklist:
- Bring a measuring tape or calipers – check axle tube and U-joint size.
- Look at the diff cover – shape and size will tell you a lot.
- Count the lugs – 8-lug hubs likely mean a Dana 60.
- Look for casting numbers – Dana often casts ID numbers into the housing.
- Check for a drain plug – a bottom plug is a strong sign of a Dana 60.
- Ask questions – get vehicle year, make, and model to confirm.
Common Misconceptions
There are plenty of myths floating around the axle world:
- “Dana 44s are weak” – Not true. They’re plenty strong for 35-inch tires and light trail use.
- “All 8-lug axles are Dana 60s” – Incorrect. Some 14-bolts and Dana 70s also use 8-lug hubs.
- “If it looks big, it must be a Dana 60” – Appearances can be misleading without proper inspection.
Final Tips for Axle Identification
To wrap it up, remember:
- Use multiple identifiers. Don’t rely on just lug count or cover shape.
- Take measurements and inspect casting stamps.
- Always verify the source vehicle.
- When in doubt, refer to axle identification charts or online communities for help.
