I need some opinions/advice on what you guys think is the best Dana 60 swap for my 1993 4.7 Stroked YJ. I still run a stock manual transmission, 35" Tires, total of 7" of SUA lift (once I swap, I may go SOA), and 4.56 gearing. I dont do a ton of off roading, but when I do I want to be prepared. This is my DD. Please let me know what you guys suggest to look for and what I should expect when installing them. Researching on JF and the internet, it looks like my best bet is a kingpin front (not sure what year is best) and a 14 bolt rear. Thanks guys.
The best Dana 60 swap is a 78-79 F350 front. most desired year and model. almost any ford Dana 60 will work, you just need to outboard the springs with some plate. depending on your skill level, that might be simple or impossible.
if you need a 60 in the front you most likely want a one ton rear... Sterling 10.25, 14 bolt, or Dana 70. All are strong.
-14 bolts are a dime a dozen with an extra pinion bearing. Its hard to find anyone that has broken one, even on 44's. they are big
-Sterling 10.25 are strong and smaller than a 14 bolt. parts are easy to get but not as much as the 14 bolt. not as common but a good axle
-Dana 70 - I know little about them besides they are big and strong.
edit - side notes.
1.you can go Dana 60 rear and still have some clearance with your 35's. not as much as a Dana35. if you are only running 35's it will be possible but hard to break a set of 60's.
2. Search and read. google is your friend.