Front Diff Chatter and Axle Swap - Ford Powerstroke Diesel Forum
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post #1 of 7 Old 08-11-2014, 07:45 AM Thread Starter
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Front Diff Chatter and Axle Swap

I am going to try to keep this as short as I can, which means I may leave out info so let me know if you need more.

The problem is when I shift into 4 I get chatter from my front end which I assume is my leaky front diff. I have a long driveway to plow all winter so I need to fix this now before the snow starts.
My 1st Question is this:
  • My truck is a 96 250 7.3 with a C5 axle code 6250 (weight rating) - Ford full float Sterling 10.25 4.10 (single rear wheel) with limed slip diff.
  • I Have a donor truck that is a 94 5.8l gaser with a 35 axle code 6250 (weight rating) - Ford full float Sterling 10.25 4.10 (single rear wheel)

Can I swap them out? Does the 35's open rear axle apply to the front axle as well? If yes, would I notice a difference in 4WD?


My Second question is if any of you know of a place to buy a complete front end rebuild kit that contains everything from the tie rod ends, to bushings, to ball bearings, etc. I know this has been talked about before, but all of the links I find are now dead. If there is not a kit, does anyone have a list of the parts I should track down. I figure if I am going to have the axle off I should do this (it needs it).

Thanks,

Also let me know if I should have posted this elsewhere
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post #2 of 7 Old 08-11-2014, 12:24 PM
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You would be money ahead to put a d60 straight axle in it. 250s are twin I beam. Cost the same to do all the tie rod ends ball joints etc. but the 60 will last longer in between needing it all done. If you could find a donor truck. F350. To get all the parts from with 4:10 gears it's a day swap. I would go through it before you put the 60 in though.


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post #3 of 7 Old 08-11-2014, 04:30 PM Thread Starter
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Thanks for responding.

From what I've seen around, that would cost me $150-300 to pick up a D60, it isn't really in the budget. That said, are there other benefits other than longevity? I haven't really read up on it because I never planned to pull my axle.
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post #4 of 7 Old 08-11-2014, 04:56 PM
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Quote:
Originally Posted by old96stroker View Post
From what I've seen around, that would cost me $150-300 to pick up a D60, it isn't really in the budget. That said, are there other benefits other than longevity? I haven't really read up on it because I never planned to pull my axle.

D60s are just a stronger axle that can take the abuse of the motor's weight along with plowing and off-roading. If you pull and rebuild the stock axle now you'll be farther behind when you end up doing an axle swap later anyways if you're going to be abusing it a lot



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post #5 of 7 Old 08-11-2014, 06:17 PM
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If you can get one for 300 it less. You are very lucky and should jump on it. I paid 500 for mine and them had to rebuild and re gear. I've heard if others paying up near 1k for an axle they had to go through. I think the 60 handles better as well as taking the abuse better and the weight of diesel. I totally understand the budget issues. But as a guy who has wasted plenty of money because it wasn't in the budget at the time and regretted it later. I would def do some research and put some serious consideration into the idea.


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post #6 of 7 Old 08-12-2014, 04:00 PM Thread Starter
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I agree, and your right, I just did a quick search and they range from 500-800. Found one about 90 Minutes from me for $200, but I have to do the front shackles, shocks, and all the steering from the tie rod on out. However, the one upside is, if not for a broken front diff I would never have considered pulling the front axle, but now that I will have done it once I will be a lot more prone to do it again. The donor truck is what I have, but after parting and scrapping the rest of the truck, I want to get another parts truck. Maybe I will be lucky and the next one will be a powerstroke and a 350!

I wish I could do it now, but I am planning on having this truck for a looooooong time. Ask me in 20 years, I plan to still have it.

Last edited by old96stroker; 08-12-2014 at 04:01 PM. Reason: wording
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post #7 of 7 Old 08-12-2014, 04:09 PM
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I hear ya on keeping it for a long time. I have more invested in both of mine than they are worth. I will have them for ever. Maybe in twenty years I can have both to where I want them to be.


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09 F150 Lariat crew cab 5.4L v8


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