The Role of Your F-250’s Axles & Upgrade Options

The F-250 is such a reputable recipe for a work truck that one would assume there are set features which would include the axles. For the most part, this is true but the F-250 could arrive with different axles depending on what features the truck came equipped with from the factory.

For the years 2011-2016, the front axle is a 35 spline Dana 60. In the back, a Sterling 10.5” axle was standard.

For the 2017-2019 F-250, the front axles are still a 35 spline Dana 60 axle. In the back, the 10.5” is still standard but trucks fitted with the Heavy Duty Towing Package are set up with a Dana M275 axle.

• 2011-2017 Front Axle: Dana 60
• 2011-2017 Rear Axle: Sterling 10.5”
• 2017-2019 Front Axle: Dana 60
• 2017-2019 Rear Axle (No HD Towing Package): Sterling 10.5”
• 2017-2019 Rear Axle (HD Towing Package): Dana M275

Weak axles have no place underneath an F-250. These trucks put out big power and are abused like no other. The abuse they will endure isn’t on account of poor vehicle owners; it’s just what these trucks are designed to deal with as work trucks. Ford knows this and has done a pretty good job with axel selections.

The Dana 60 is a very stout axle assembly that features 35 spline axle shafts and which Dana says is capable of handling up to a 38-inch tall tire in stock form. The Dana M275 is the perfect match for the 60 as a rear axle. This unit features 36 spline axles, a 10.8-inch ring gear, and an optional locker. The 10.5-inch axles may not be the Heavy Duty axle but are still very capable. The ring gear is still massive at 10.5 inches and is paired with 35-spline, 1.5 inch thick axles.

Every axle is bound to have drawbacks. Even Ford’s choice axles are subjected to this. In daily use, each one of these axels is going to be near bulletproof, but once put to the test things can become apparent. The Dana axles are known to spin bearings under extreme load while the Sterling 10.5 axle is known to snap the welds in the center section. Other than these potential issues, there a few short drawbacks aside from the weight of the Danas.

When put under serious stress and paired with big power and max traction, these issues tend to show up. These problems usually occur when the tires are spinning freely and suddenly gain traction. This will result in a powerful shock to the rear that can spin bearings, snap axle tubes or even snap axle shafts.

There are a few reasons to upgrade an axle. The biggest reason is to raise durability. Factory axle shafts are constructed of steel, which is going to take only so much abuse. The first upgrade to make as you plan a serious off-road build or puller out of your F-250 is upgrading to chromoly shafts. This material is much stronger and will greatly reduce the chance of snapping the axle shaft.

For traction, one will spend their time and money modifying the differential and ring and pinion gears. Moving from the factory unit to an aftermarket locker or locked differential will raise durability and possibly increase traction depending on what style differential the truck was already equipped with. Regearing the axle with lower ring and pinion gears is a sure-fire way to improve traction.

There’s no set fix for the Dana bearing issue other than being mindful of the axles. With the Sterling 10.5 inch, one can locate and address weak welds on the center section of the axle where the tubes are connected. Adding strong welds will reduce the likeliness off snapping the axes free of the center section.

Axle maintenance is easy. This is particularly true in the case that a locker style rear is present rather than a limited slip. Limited-slip axes have clutches which will need to be replaced with time where lockers do not. Also, no friction modifier needs to be added to the gear oil. Regular maintenance and inspection of the fluid are needed in any case, but with an off-road truck, it’s even more critical. Inspecting fluids, bearing condition and the condition of the mechanical parts must be performed more regularly on account of high heat and hard use.

Being mindful of the axles and avoiding abuse is only going to prevent so much. There are many instances where an unavoidable situation leads to a broken axle. If you are on a job site or the trail and break an axle you will feel grinding, thudding or a large bang if the center section smashes into the floor pan. You will be stuck wherever the truck sat when the axle snapped as there will be no power transferring to the wheels of the axle that broke.

There are many tricks one can pull to limp their truck home. None of which should be suggested as they can cause further damage to the vehicle or even cause harm to the driver. The best thing to do is link a tow strap to a buddy’s rig that can pull you out of the woods and having a flatbed come and tow the truck home.