1997 F250 4x4 D50 to D60 front axle swap? - Ford Powerstroke Diesel Forum
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post #1 of 12 Old 04-08-2013, 08:13 AM Thread Starter
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Question 1997 F250 4x4 D50 to D60 front axle swap?

Hi all,

So, if there is a good thread that already answers all or most of my questions, please feel free to direct me to it.

1.I'm wondering what all is needed to do this swap. A complete new parts list and a list of all of the D50 parts, if any, that can be reused ...brakes, hubs, ball joints (i just replaced them!), gears (I have 3.55s), etc?

2. Also, if I do a stock-height swap (no lift, stock 350 springs) how much of a lift will I get over the stock F250 clearance and is there a difference in the stock rear height between the 1997 F250 and F350?

3. Finally, I know folks always throw around figures about how cheap (relatively) it is to do these mods, but I'd like some "real world" estimates on doing this (<$1,000 or >$1,000). Maybe, some folks that thought it was going to be cheaper than it ended up?

If you could put your responses relative to the question #s, I'd appreciate it.

All help greatly appreciated.

James
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post #2 of 12 Old 04-08-2013, 09:25 AM
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Dana 60 Conversion for F250 years 1986-1996 .: Articles

1. I would replace all steering joints, brake parts, ball joints, and Ujoints when you do the swap before you put the axle in. The spindles do not swap, everything on the spindle swaps, except maybe the rotor depending on the year. Edit - and replace any axle seals that a leaking as well.


2. I think you may gain possibly an inch, but I am not sure.

3. My costs all said and done to do JUST the axle swap will be around $1200. I replaced everything on my Dana 60 from the inner axleshaft seal out.

Gerry

'97 CCSB f-250 4x4 auto, 6pos chip w/ canned tunes, AFE intake, 4 in exhaust, 3in dp, 3.55 gears,
Dana 60 rebuilt and waiting to be installed
184k
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post #3 of 12 Old 04-08-2013, 12:22 PM Thread Starter
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So something like this one? Do I need to pay attention to the description--King Pin, High pinion, driver's side drop, etc?

Kingpin Dana 60 front axle Ford HIGH PINION Jeep, crawler, Chev IFS

Thanks,
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post #4 of 12 Old 04-08-2013, 12:32 PM
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Yes, but I paid 600 for my axle, not 1000. However, that may not be bad if the axle doesn't need a rebuild, as mine will hit 1000 with all new parts.

You will also need the following:
Track bar
Track bar mounting bracket
Drivers side U-bolt plate (nearly impossible to find otherwise)
steering linkage (attached in that picture)
sway bar set up (not necessary, many never install the sway bar)
stock F350 springs (250 springs are too stiff)
F350 drive shaft and t-case yolk

Edit- I would also try to find one in a gearing that matches your truck (3.55 or 4.10)

Also, If you fill in your signature with details about your vehicle that will help forum members help you.

Gerry

'97 CCSB f-250 4x4 auto, 6pos chip w/ canned tunes, AFE intake, 4 in exhaust, 3in dp, 3.55 gears,
Dana 60 rebuilt and waiting to be installed
184k
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post #5 of 12 Old 04-08-2013, 12:37 PM Thread Starter
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Thanks, yes this one is in my gearing too.

How about the terms I mentioned? Are they all that way, if they are 1988+ D60s?

Thanks again.
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post #6 of 12 Old 04-08-2013, 12:47 PM
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Quote:
Originally Posted by 97stick View Post
Thanks, yes this one is in my gearing too.

How about the terms I mentioned? Are they all that way, if they are 1988+ D60s?

Thanks again.
The kingpin dana 60 is a bit different from the the ball joint, but It will still bolt right up to your truck. I have a ball joint, and recently rebuilt it, so that is what I know more about. However, many will say that the Kingpins are more durable. They also command a higher price from what I have seen. I was fine with the ball joint axle, as I do not plan on abusing my truck in any way, and the ball joint axle should be more than enough for my purposes. I believe In 1992 or 93 ford switched over to the ball joint axle, and I believe all ford axles have a driver's side gear housing, which is what we need in our trucks. What is important is that it comes from a ford f350 from 1997 or older, and has the same gears as the truck it is going into.

Gerry

'97 CCSB f-250 4x4 auto, 6pos chip w/ canned tunes, AFE intake, 4 in exhaust, 3in dp, 3.55 gears,
Dana 60 rebuilt and waiting to be installed
184k
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post #7 of 12 Old 04-08-2013, 12:51 PM
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Also, I am learning on the fly, I haven't even completed my swap yet, but I have been asking a lot of the same questions you are so I am just sharing what I know.

Gerry

'97 CCSB f-250 4x4 auto, 6pos chip w/ canned tunes, AFE intake, 4 in exhaust, 3in dp, 3.55 gears,
Dana 60 rebuilt and waiting to be installed
184k
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post #8 of 12 Old 04-08-2013, 12:52 PM Thread Starter
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Great. Many thanks.
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post #9 of 12 Old 04-08-2013, 01:25 PM
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I ran a king pin and a ball joint axle, no real difference other than that in them, the 94 and under axle has slide pin calipers, so just keep in mind your gonna have to grind the tab off your brake lines, the 95-97 brakes are bolt on, but the rotor is different, so 95-97 axles will bolt into your truck rotors, hubs, calipers are interchangeable, the 86-94 axle only supports the hub, you will need rotors, and calipers to come with it, but for the most part is still bolt in

-Kris-
2011 f150 ecoboost 4x4 323/452 on php dyno 11/16/13
1995 CCLB DRW 324K
2001 CCLB DRW 319K
Dp tuner infinity, exhaust, intake, chipped, tricked, and wrecked


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post #10 of 12 Old 04-08-2013, 01:33 PM
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The biggest difference between the BJ and KP is now the knuckles mate up to the axle. I have a 93, your life will be a bit simpler and more streamlined if you get a 95-97. My job would be done if I didn't still have to do brake calipers and rotors, because I could just swap everything over.

Gerry

'97 CCSB f-250 4x4 auto, 6pos chip w/ canned tunes, AFE intake, 4 in exhaust, 3in dp, 3.55 gears,
Dana 60 rebuilt and waiting to be installed
184k
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