Getting some air in a stock F-250

'91 Ford F-250 Build-Up By Greg Carter Technical Wizardry Steve Shaw

Contents

Background

Front Axle
From 1980 to 1996 all F-250s had Independent Front Suspensions (IFS), early F-350 also had IFS front suspensions.  In 1986 Ford started putting Dana 60 solid front axles (the monobeam) in F-350s but F-250s still had IFS with either Dana 44-HD or Dana 50 axles.  The Dana 44 is considered too weak when running 35" tires and a locker, the Dana 50 has larger axle shafts than the 44 but only slightly larger ring gear and suffers from lack of available aftermarket parts (limit of 4.10 gear ratio, no detroit locker).  One alternative to the aftermarket parts problem is to use a Dana 44 3rd member from a F-150 (if you have the Dana 50) with a Detroit locker modified to accept the Dana 50 30 spline axles, which any good drive train parts supplier should be able to get.  But you'll probably blow up the diff if running 35" tires.

Unlike the coil spring F-150 the F-250 has a front leaf spring suspension which is identical to the leaf spring set up found on F-350s.  This is where things get interesting, if you can find a wrecked F-350 from 1986-91 you can toss your Dana 50 IFS (and the comfy ride) and replace it with the bullet proof Dana 60 from the F-350.  1992-96 may benefit from the swap as well, but I believe the frame dimensions changed for those years so I can't say for sure if the spring pads, steering linkage, etc... will interchange.  However after a few minutes with a tape measure you'll know.

You'll need all the steering linkage from the pitman arm (including the pitman arm) on down, the track bar and cross member bracket, sway bar and brackets (make sure to get the ones that bolt to the frame), one u-bolt bracket (the other is welded to the axle housing) and driveshaft.  Make sure the goon cutting the axle out of the truck is careful, he'll be tempted to cut through the track bar bracket and/or bar and sway bar rods.  If the yard wants too much for the steering linkage it maybe cheaper to just buy it all new, most likely it will be worn and need replacing any way.

If you plan on a gear change and locker the time to do it is before you install the new Dana 60.  Its much easier to install and setup the gears with the differential in an open spot, than laying underneath your truck.  In fact I would never attempt to do it with the differential installed.

Rear Axle
Some 1986-96 F-250s came equipped with a semi float c-clip Ford 10.25 rear axle, earlier years had Dana axles.  Semi float axles have a lower weight rating and don't fail gracefully.  The wheel will fall off when an axle is snaped.  With a full float axle you can remove the broken axle and continue driving.    Another draw back is that there is no locker available for the semi float (correction, you can get a Lockright but this isn't recommended for serious off road use with 35" tires, it isn't strong enough especially for the rear).  Full float 10.25 axles came on all 1986-96 F-350s and some F-250s.  You can recognize full float axles by the large hub, no hub then its not a full float.  My F-250 had a semi float axle, out it came.

Cost Overview

I've tried to keep track of all the costs so you can get a more accurate idea of how much the swap will really cost you , not included are special tools bought during the swap. Ever tried to remove an upper king pin? you need a 7/8 hex (male) socket with a 3/4 drive.  The pin takes at least 700 ft lb. of torque to remove, I had an 8 foot bar attached to the 3/4 drive socket wrench to break it loose.  The one socket cost $55.

If you are happy with the stock gears (4.10 or 3.55) in the Dana 60 and they match your rear axle and you don't want a locker than you'll save a lot.

Front Axle - Dana 60

ITEM	Part Number	Price (Canadian)	Price US ($1= $1.5 Can)
Used Dana 60	-	$600	$400
Right Tie Rod (shorter)	Moog DS1068	$177.17	$118
Tie Rod Left Inner (From above item To Pitman arm)	Ford E7TZ 3304 B	$100.00	$66.67
Tie Rod Left Outer, note this has the same part number as above item, cheaper at Ford	Canadian Tire 22-3591-2	$111.00	$74.00
Percision Gear Dana 60 4.56 Gears	Drive Train Direct PG60D/456R	$350.55	$233.70*
Detroit D60 35 SP 4.56 Up	Drive Train Direct  DL225SL-29A	$667.5	$445.00*
Overhaul Kit	Drive Train Direct  SA35-2034	$120.00	$80.00*
Dana 60 Axle tube seal	Drive Train Direct  DS36487	$15.00	$10.00*
U-bolts / Nuts Front	-	$27.68	$18.45
2 Front Hub Seal	ZD 06-415960	$24.98	$16.65
2 Front Axle U Joints	ZD 06-374 (greaseble)	$118.76	$79.17
2 Spindle Bearing Kit	Canadian Tire 93-1300-8 or SBK3	$41.98	$27.98
Upper King Pin	Ford D6TZ 3115 A	$25.42	$16.94
Lower King Pin race	Ford CITZ 3126 A	$14.50	$9.66
Lower King Pin Bearing	Ford D6TZ 3113 A	$19.00	$12.67
Lower King Pin Cap	Ford D8TZ 3123 A	$7.35	$4.9
Upper King Pin Seal	Ford E5TZ 3254 A	$11.19	$7.46
Lower King Pin Seal	Ford E5TZ 3332 A	$21.30	$14.2
Upper King Pin Spring.  Note do NOT buy this at Ford, they want over $45!	Spicer 37300	$5.24	$3.49
Upper King Pin Bushing	Spicer 41886	$5.98	$3.96
General Motors Gear Marking Compound	GM (ah!) Part   1052351 Compound 08800	$7.00	$4.67
Drive Shaft Shortened 1"	- Labour	$32.00	$21.33
Drive shaft U-joint	5-213X or UJ270	$23.41	$15.60
Total	-	$2527.01 (holly *&@^!)	$1684.50

 
Rear Axle Ford 10.25 Full Float

Used (blown) 10.25 Axle	-	$125
TSM Disk Brake Conv.	-	$448.85	$299*
2 1980 Chev 1/2 ton calipers	Canadian Tire 13-2072-6, 13-2073-4 or   C526, C527	$77.98 ($38.99 each)	$51.98
2 3-9/16 Clamp - Holds bracket for brake line	Canadian Tire 63-2125-2	$1.98 (.99 each)	$1.32
Brake Pads	Canadian Tire 13-0122-0 or D526	$23.99	$15.99
Flexible Brake line From 78 Pontiac Perisian w/350 (1 only, had one good used one)	Canadian Tire 13-4512-2 or BH36797	$28.99	$19.32
2 Brake line clip (U shaped), flex to steel line	Canadian Tire 13-7319-2	$2.58	$1.72
Jamar Brake Lock (for parking brake)	JC Whitney 85DN6592Y	$35.93	$23.95*
Superior Ring & Pinion Gear Set	Drive Train Direct  SAF102456	$303.00	$202.00*
Overhaul kit	Drive Train Direct  SA35-2046	$163.5	$109.00*
Detroit Locker	Drive Train Direct  DL225SL-56A	$729.76	$486.51*
10.25 Axle Oil Slinger	Ford - D5AZ 4670 A	$2.21	$1.47
2 Hub Seal, Note I would go with the Ford Seals, not only cheaper but better made. But I had already installed the others...	Canadian Tire 13-8261-0 or Ford F4TZ 1177 B ($20.82 each)	$69.98	$46.65
2 - 2" Wheel Spacer	Performance Wheel & Tire  Englewood CO  303-934-2929	$285.00	$190.00* ($95 each)
Total		$2298.75	$1448.91

 * Bought from US distributor, all other parts were bought from local Canadian sources.  Note about Canadian prices, while I provide a rough conversion to US dollars you may find that the US prices above are lower than what you can find.  That is because generally a 5 dollar part in Canada is a 5 dollar part in the US, well for common parts anyway.
 

More...
Dana 60 Rebuild, Rebuild of Dana 60 Including Detroit Locker, 1986 - 1996 F-250 Dana 60 Conversion, Ford 10.25 Full Float Axle Rear Disk Brakes and Rebuild, MileMarker Winch Installation.