The Dana Ultimate 60 Axle is a great starting point for any serious Jeep build planning to run 40-inch, or larger, tires. And the team at Down2Mob Overload just documented the entire swap. To prepare their 2020 Jeep Gladiator for a future with massive tires and a heavy overland camper, they ditched the factory axles for a set of one-ton crate axles from Dana Spicer, transforming the truck into a true heavy-duty machine.

Choosing the Dana Ultimate 60 Axle

The Ultimate Dana 60s are a massive upgrade over the stock parts. These complete crate axles come with huge Ram 3500-equivalent brakes, beefy Warn 35-spline locking hubs, and move to a much stronger eight-lug wheel pattern.

When it came to choosing the differentials, the owner, Phil, opted for strength over convenience. “E-lockers are going to be easier to install, air lockers are going to be stronger and more reliable,” Phil explained, “so to me that’s a no-brainer.”

The Installation and Supporting Mods

The video shows the crew at Nichols Auto Fab pulling the old, worn-out axles from the Gladiator and wrestling the new, much larger Dana 60s into place. The swap required a number of supporting modifications to go along with the new hardware.

A heavy-duty Steer Smarts Yeti tie rod was brought in to handle the steering duties. The move to an eight-lug bolt pattern also meant a new set of wheels was needed.

Lessons Learned and Future Plans

Tearing the truck apart also revealed some old trail damage and prompted future upgrades. Phil discovered he had previously bent a rear bump stop pad from a hard hit.

He also recounted how he had ripped the end link mount clean off his rear sway bar on a previous trip. In a cool twist, he noted that the company used his experience as a real-world test.

The Foundation for Adventure

The installation of the Dana Ultimate 60 axle set is the most critical step in this Gladiator’s transformation. It’s the foundation that will allow the truck to handle the stress of 40-inch Nitto Trail Grappler tires and the weight of a Bison Overland camper, a future where the truck bed will be permanently removed. As Phil put it, “These Dana 60s will never see a real truck bed.  You’re overland axles now.” The swap is a massive undertaking, but for a build this extreme, it’s the only way to ensure the truck is strong enough to handle any adventure.