Yo B,
Here is some Dana 60 info;
Dana 60, Best Years for SAS; "...85-97 for a bolt-in swap..."
Source: by Dustin S (Dustball, Mellow Yellow, Mr. Laser Boy
Information & Parts Sources.. EXCELLENT
Source: by ocalabronco at Ford Bronco Zone Forums
Installation, Dana 60 in a 95 (SAS)
Source: by Ian L (stangmata, stangmata50l, Bronco)
Installation, Dana 60 in a 95 (SAS)
Source: by Pony-Boy (Repo'd, Blackhorse, Howard S)
Installation in a 95 (SAS)
Source: by JoeBob1901 (Joseph B)
Installation in a 94 (SAS)
Source: by BigBad94Bronco (L.I. Monster Bronco, HAD2DOIT, 1Ton94Bronco, Joe D)
Installation, rear in a 93
Source: by 2bitbronco (nobs)
Installation, rear w/VSS in a 95
Source: by Shadofax (TheJuice, The Juice, Mark Z)
Parts Break-Out Diagrams w/ Auto & Manual Locking Hubs & BoM; 6 MB PDF
Source: by www 2.dana.com
Description & Operation, Diagnosis & Testing, Removal & Installation, Disassembly & Assembly Procedures, Specifications, & Special Service Tools/Equipment in a 96 from 1996 F-150, F-250, F-350, and Bronco Workshop Manual
Source: by Ford
and fyi;
96 Bronco-F-Series Workshop Manual by Ford
https://www.motorcraftservice.com/pubs/content/~WSTJ/~MUS~LEN/21/STJLEFT.HTM
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EFI 5.0L to EFI 5.8L swap by Ryan M
EXCERPTS:
It's not easy to pick a 302 from a 351 in a line up.
One quickest and easiest way to ID a EFI302 from EFI351 is to inspect the EGR system. They use different exhaust tubes to connect the EGR to the exhaust. The 302 gets exhaust from the lower intake, while the 351 gets exhaust from the passanger exhaust manifold. Much quicker and easier than measuring the lower intake.
The positive ID is to measure the lower intake
302 is aprox ~ 8 inches wide
351 is aporx ~ 11 inches wide
New Intake need upperand lower, the gasket patern is diffrent from 5.0L/5.8L. So you can't mix an upper and lower between the two. The 5.0L uses squared ports and the 5.8L uses oval ports. If you get an intake from a junk yard it will have the matching fuel rail.
Fuel Rail: The 5.8L is a wider engine so the fuel rail is wider. You can get this with the intake from the junkyard. Some people have cut the nylon tubing off the 5.0L fuel rail and used EFI fuel hose to make it wider.
Distributor - the 5.0L/5.8L distributors look the same but... The only difference between them are the oil pump drive is larger on the 5.8L.
Computer - You must get a 5.8L computer from a truck just like your 5.0L. If you have a E4OD transmission you must get a 351 computer from an E4OD truck. You should be able to get this off a junkyard truck just like the intake. Just don't get one that was on a flood damaged vehicle
/emoticons/
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Exhaust Crossover - The 5.8L is a wider engine so to connect to the exhaust manifold you'll need a wider corssover. There are a few options to acomplish this. The stock crossover's are part of the first converter, so it is an expensive part to buy new. You can get it used, or have an exhaust shop build you something custom.
remember to keep O2 sensor and install it about 6-12" away from the cylinder head
Oil Pan - The 5.8L has a larger crank with larger main journels. So the oil pans are not interchangable.
EGR - They use different exhaust tubes to connect the EGR to the exhaust. The 5.0L gets exhaust from the lower intake, while the 5.8L gets exhaust from the passanger exhaust manifold.
See pics.
