96 Dually 4x4 build - Ford Powerstroke Diesel Forum
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post #1 of 168 Old 07-11-2014, 05:44 AM Thread Starter
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96 Dually 4x4 build

I just started on my 96 dually and decided to do a build thread. I am starting with a 96 rust free 2wd dually. It should be a pretty quick build since the body is in such good shape. The truck has 416K miles on it.

I bought a 97 f350 4x4 cab and chassis truck that had an interior fire. The truck had 130K miles on it when it burnt. I am going to transfer the drive train over to my frame. It will be nice to have a drivetrain with 300K less miles on it.
I put the parts truck up on the lift in my garage and started disconnectiong everything for removal the other night.
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post #2 of 168 Old 07-11-2014, 05:54 AM Thread Starter
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The interior is in pretty rough shape. It has mis-match seats and some of the panels are faded. I am having the seats recovered in leather and going to dye the panels grey.


My interior guy called and told me he had some time to get to my headliner and seats so I started tearing them out last night. It went pretty quickly. I had the head liner out in about an hour. I had to remove the back window to get it out. I did find some surface rust on the interior lip around the window. I'll clean that up later before I put the head linner back in. My 11 year old helped me get the window out and back in. I am glad my boys are big enough now to help with some stuff. I am dropping it off at lunch time today.

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post #3 of 168 Old 07-11-2014, 08:10 AM
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Looks like a nice project. I am doing a similar project but I am taking a 4X4 SRW and turning it into a Dually. Don't forget that the front frame rails are different on a 2wd vs. a 4X4. You have to box the front frame rails or they won't be strong enough to support the spring shackles. I am sure you already knew that because it looks like you know what you are doing. But, Just in Case I thought I would throw it out there.

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1997 Crew Cab Long Bed 4X4 (DRW Conversion) Auto. 280K miles
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Fresh Turbo with 1.0 Housing & Wicked Wheel II, 3" downpipe with 4" exhaust, Intercooled, 6.0 Fan, 39 gal rear fuel tank + 70 gal Transfer Flow in the bed, Hydroboost, Completely New Suspension (Springs, Shocks, Bushings),08 Rear Diff Cover, Baby Swamps, Hydra Chip with Swamps Tunes, and Swamps IDM, Dually Swap, Tru-Trac locker in the rear, Red Head Steering Box and Borgeson Steering Shaft


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post #4 of 168 Old 07-11-2014, 09:20 AM Thread Starter
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Thanks for the heads up but I did know. I am taking the inner sections out of the other frame and welding them into mine. I also have a PMF RSK kit going on it.....I am going to make a front bumper after everything is in place. I cant see spending 1200 on a bumper I can make for 200.....

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post #5 of 168 Old 07-11-2014, 12:28 PM
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I wish I could build a Ranch Hand for 200 ish. I have the skills but lack the big benders and welders it takes to work that heavy of material.

1997 Crew Cab Long Bed 4X4 (DRW Conversion) Auto. 280K miles
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Fresh Turbo with 1.0 Housing & Wicked Wheel II, 3" downpipe with 4" exhaust, Intercooled, 6.0 Fan, 39 gal rear fuel tank + 70 gal Transfer Flow in the bed, Hydroboost, Completely New Suspension (Springs, Shocks, Bushings),08 Rear Diff Cover, Baby Swamps, Hydra Chip with Swamps Tunes, and Swamps IDM, Dually Swap, Tru-Trac locker in the rear, Red Head Steering Box and Borgeson Steering Shaft


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post #6 of 168 Old 07-11-2014, 02:48 PM Thread Starter
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I'm lucky.....friend has a shop with a big press
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post #7 of 168 Old 07-11-2014, 03:30 PM
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I was wondering how people get the headliners out of crew cabs, I have been planning on re doin mine also.

Good luck with the build, looks like you have a good start on it.

Yours will look a lot like mine.

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post #8 of 168 Old 07-11-2014, 03:41 PM
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You do know the frame width is different on a cab n chassie from the cab back, The rear diffs wont swap over, different widths..... just a heads up....


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post #9 of 168 Old 07-11-2014, 04:20 PM
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His truck is already a dually so all he should need is the D60 front axle. He can keep the rear from his 2wd as long as the gears are the same.

1997 Crew Cab Long Bed 4X4 (DRW Conversion) Auto. 280K miles
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Fresh Turbo with 1.0 Housing & Wicked Wheel II, 3" downpipe with 4" exhaust, Intercooled, 6.0 Fan, 39 gal rear fuel tank + 70 gal Transfer Flow in the bed, Hydroboost, Completely New Suspension (Springs, Shocks, Bushings),08 Rear Diff Cover, Baby Swamps, Hydra Chip with Swamps Tunes, and Swamps IDM, Dually Swap, Tru-Trac locker in the rear, Red Head Steering Box and Borgeson Steering Shaft


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post #10 of 168 Old 07-11-2014, 06:01 PM
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I was just giving him a heads up in case he was wanting to put his body on the other frame, or planning on using the other diff. I'm thinking he was considering the mileage difference.


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