It's funny how one component can make or break the image of a truck. When General Motors announced in 1991 that its 1-ton pickups were switching to independent front suspension (IFS), there was a cry heard around the world. That cry was for the loss of the Dana 60 front axle that had been fitted to every four-wheel-drive 1-ton GM pickup since 1977. That cry still echoes to this day.
Ford and Dodge truck engineers must have rejoiced over the news. For in the heavy-duty truck market, there's no substitute for the simplicity, strength, and reliability of a solid axle. Maurice Rozo of Burbank, California, couldn't agree more. As a Chevy guy, he cringed at the loss of the Dana 60 axle in the GM lineup. Unlike the rest of us who could do nothing but complain about it, Maurice came up with a solution. He built his own GM solid axle suspension kit.
BORN IN BURBANK
Working with a team of fabricators and designers at his shop, Off Road Unlimited (ORU), Maurice spec'd out a kit that would allow '92-and-newer GM 3/4- and 1-ton truck owners to install a Ford-style Dana 60 front axle in their truck utilizing commonly available leaf springs. Off Road Unlimited made a name for itself offering this kit to the public, as well as developing other proven off-road suspension, steering, and drivetrain products.
Over the years, most of the solid front axle GM trucks that you've seen on the road are either running ORU parts, or appear to have taken cues from the ORU kit. We've even seen Jim Carrey, the famous actor, driving a 3/4-ton solid axle GM truck that Off Road Unlimited built.
Recently, Off Road Unlimited has revised its solid axle swap kit to not only work with General Motors' latest GMT900 3/4- 1-ton chassis, it's now developed a package that includes a four-link suspension and coilover shocks for '01-and-newer trucks.
A Dynatrac Pro 60 front axle built with an ARB Air Locker, 4.56 gears, 35-spline axle shafts, and Off Road Unlimited ram-assisted crossover steering feeds Maurice's solid axle addiction. | 
In the Line-X protected bed, Maurice carries a Transfer Flow auxiliary fuel tank/toolbox and a Power Tank CO2 bottle for airing up the tires. | 
Under the hidden flap in the floor of the bed is a Warn 16.5ti winch. |
Maurice Rozo's '07 Chevy 2500HD Duramax began life as a two-wheel-drive truck and was upgraded with a four-link front suspension, Dana 60 axle, divorce-mounted Atlas transfer case, an 8-inch lift, and 40x13.50R17 ProComp Xterrain tires. As you delve into his creation, you'll notice both the front bumper ends and the rear wheel wells were cut apart and modified to clear the huge 40-inch tires. You'll also pick up on the blacked-out emblems that were color-matched to the Amp Research Power steps and Defender roof rack and light cage. | 
For off-road use, Maurice's 2500HD runs on a set of 40-inch ProComp Xterrains mounted on 17x10 ProComp wheels fitted with Champion C-3 style beadlocks. | 
The rear AAM 1150 axle has been fitted with 4.56 gears, an AAM TracRite helical-gear type limited-slip differential, and an ORU finned aluminum differential cover. From this angle, you can also see the Gale Banks Engineering dual exhaust, King reservoir shocks, Atlas leaf springs, and the mount for the hidden Warn winch that's stashed under the pickup bed. |