D60 Swap Questions - Ford Powerstroke Diesel Forum
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post #1 of 13 Old 08-13-2014, 07:32 AM Thread Starter
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D60 Swap Questions

I finally got my hands on a OBS RCLB. I've been looking for a clean one for a while and low and behold, last week I took one in on trade at a dealership I work for.

'96 F250 RCLB XL, 4WD, 7.3L w/ Auto, Chrome effects, Alcoa Wheels.

The truck has 382K miles and was taken very good care of. My girlfriend and I plan to restore the truck over time.

It needs quite a bit of work in the front, and I'm already thinking that if I'm going to rip it apart, I really want to do a D60. Obviously there are tons of threads on this, and I could Google search write ups on it, but I'm looking for the following information -

1. What is all needed for the swap? Ford P/N's would benefit me.

2. Did the F250 have two optional rear diffs in '96 so I need to make sure what front axle I source matches?

3. If I plan to lift the truck 4" what parts could be done at the same time?

4. Places to source parts?

5. Ballpark estimate on this swap.

I've known the basics with these trucks but slowly starting to build more of a knowledge base.

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post #2 of 13 Old 08-13-2014, 08:40 AM
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Rsk for the front pmf and sky manufacturing both make them
Any dana 60 from a f350 years 87-96 will work
check the axle code in the drivers side door jam look at the axle code to see what gears it has and find a d60 that matches

95 f250 eclb 4x4 under construction
96 f250 eclb 4x4 rosewood stage 1 injectors, bully dog 6 position chip, 6637 air filter, idm mod
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post #3 of 13 Old 08-13-2014, 09:22 AM
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Use the search bar, there's probably 10 or more write ups on this. The ballpark price varies alot, depends on what what axles cost in your area, what condition it's in, etc. But I would say at least 1500 to get the axle and get it lifted some. A good 4-5" lift is gonna run you 1200-2000 alone.

Rob
'95 F350 CCLB, "Project Moneypit", ZF5, 4x4, straight piped, DIY E-fuel, more coming

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post #4 of 13 Old 08-13-2014, 02:19 PM
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track bar, track bar bracket (or a drop bracket with a lift), front springs, axle, brake lines with a lift, drop pittman arm, driveshaft may need to be lengthened depending on the lift. if you get an older 86-95.5 D60 you will have the slide pin brakes, make sure you get the calipers.

a D60 swap will net you 2" over the f250 stance. PMF and sky both make a RSK (as was mentioned) that will net another ~2.5.

as for axle codes c5 and 35 are 4.10s, c9 and 39 are 3.55s.

ball park $2000 to buy the axle go through it and replace what needs replacing, new brakes, ball joints, bearings/seals etc, and get it installed, then add your lift.

best place for parts is to find everything off of a donor truck. PMF sells alot of the smaller parts but they are spendy.

94.5 F250 Reg Cab 4x4 5 speed 4.10 276000 plus miles

97 F350 Crew Cab LB 4x4 5 speed 3.55 320000 plus miles (parts truck)



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post #5 of 13 Old 08-13-2014, 02:28 PM Thread Starter
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Thanks. After I posted this I found the axle code in the door jamb. C9 so it has 3.55's.

I found a local guy selling a 97 F350 D60 with 4.10's, springs, steering box, he claims has everything for $750/pickedup

The 4.10 gears are simply interchangeable in the stock axle housing from the F250, correct?
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post #6 of 13 Old 08-13-2014, 02:29 PM
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My sas cost $500, I got everything from a 1993 f350, springs, trac bar, trac bar mount, calipers, rotors, hubs, I cut the tab off my 97's brake lines and bolted them to the 93 axle, done

Found it on Craigslist

-Kris-
2000 excursion V10 2wd 230k
2000 Excursion 7.3 4x4 246k
1995 CCLB DRW 324K
2001 CCLB DRW 319K
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post #7 of 13 Old 08-13-2014, 05:13 PM
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Quote:
Originally Posted by GallopingFord View Post
The 4.10 gears are simply interchangeable in the stock axle housing from the F250, correct?
no a D60 uses a 9.75" ring gear

a D50, what is under the 250, uses a 8.5" ring gear

and if you swap gears some with another set you will need to set the gears up properly

94.5 F250 Reg Cab 4x4 5 speed 4.10 276000 plus miles

97 F350 Crew Cab LB 4x4 5 speed 3.55 320000 plus miles (parts truck)



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post #8 of 13 Old 08-13-2014, 09:02 PM
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^^ and a bearing set to swap gears is around 150$

Rob
'95 F350 CCLB, "Project Moneypit", ZF5, 4x4, straight piped, DIY E-fuel, more coming

'63 Jeep Truck, Chevy motor, Ford 9"


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post #9 of 13 Old 08-14-2014, 09:50 AM
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Stick with a 95 and newer donor D60. Let's you spend some time upgrading your existing brake lines (to longer) and and refurb your calipers ahead of time and reuse them on your donor.

As for "I could Google search write ups on it, but I'm looking for the following information...", well, that is why you google search the write ups, it really is worth your time to do this. There are much better write-ups than mine but I inserted pictures I thought would due helpful. The link is below in my signature.

Good luck! I was in your position about 3 or so years ago when I started planning mine.

Denton, TX

I envy those that know exactly which modification to make and in the most logical of sequences. But not enough to trade for my meanderings and misfires.

1996 F250 crew cab/short bed, 4x4, auto PSD, 6637 air filter, interior grab handles, stainless window vents, remote door locks work with engine running mod.
Link to my D60 refurb and OBS swap thread
Link to my OBS air vent R&R thread
Link to my grab handle install
Link to my tire size comparison pics

Last edited by leojr; 08-14-2014 at 01:22 PM.
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post #10 of 13 Old 08-17-2014, 07:22 PM Thread Starter
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Quote:
Originally Posted by terryknight View Post
no a D60 uses a 9.75" ring gear

a D50, what is under the 250, uses a 8.5" ring gear

and if you swap gears some with another set you will need to set the gears up properly
Sorry, I should have been more clear. I was referring to the rear axle, since I'd have to swap them out to 4.10's to match the D60, correct?
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