Is it possible to put 5-lug wheels on the front of an F-250 4X4 that currently has 8-lug wheels? Current rear diff. is open and I have a 9" Ford LS I would like to use. Any way to get around this difference in wheel size/lug number? Already have 5-lug wheels with good tires.

 

No.

Your 9" swap would be a downgrade in housing strength, and if you have a full floater in there now, make it a double downgrade.

Sell your 5 lug wheel/tire set up and, if you need new tires, buy new tires that work on your truck.

If you want 5 lug wheels, sell your truck and buy an F100 or F150.

 

I'm not that concerned with housing strength as much as the limited slip functionality.

I already have an F-150 4x4; that is where the 9" LS rear axle is coming from. The F-150 also has a strong 351W and C-6 auto. Unfortunately the frame and body are eaten up by road salt. Welding the frame on the F-150 was estimated at $1K and that still leaves the body in bad shape.

The F-250 4x4 does not have a full float rear axle, it is a Light Duty F-250. It has a weak, oil-slinging 302, M5OD trans. and 10.25 non LS rear. The frame and body are in good shape.

I was trying to figure out a way to make one good hunting truck out of the two by swapping components without breaking the bank.

 

you can convert either the front d44 ttb to 5 lug or the 9" to 8 lug. but that would be nothing short of foolish, considering wheels are so cheap and such conversion is time consuming and costly. . .it'd kinda suck to have 8 lug wheels up front and 5 lug wheels in the back, but its the only way to accomplish exactly what youre talking about without literally throwing your money away.

if limited slip is all youre after:
1) buy a limited slip for the 10.25, done ( a clutchless limited slip is far superior to any stock unit that was probably worn out 100k miles ago)
2) find an 8 lug limited slip axle and swap, done (assuming the LS isn't worn out)
3) swap your 9" (assuming the LS isn't worn out) and buy 2 5 lug wheels for your tires

they will all be about the same price in the end, I don't think I need to illustrate which one is best and why.

 

Just throwing this out there.. is the 8-lug hub the only difference between the D44 and the D44HD? Would a 5-lug hub and spindle swap onto the HD TTB arms or would the whole TTB assembly have to be changed?

 

the 44HD uses bigger steering knuckles, spindles, bearings, and hubs (8-lug) than the Dana 44. the only components interchangeable between the 44 and 44HD are the hubs and diff pumpkin.

so yes, he could swap the hubs...but it would still mean swapping a rear axle and swapping out some 5 lug hubs. in addition, you have to figure at some point 8 lugs is better than 5.

 

Swapping the hubs was exactly what I was wondering about. I know that putting in a LS unit for the 10.25 would probably be the best but since they start at about $650 + install, that pesky money issue pops up again.
I know that the LS in the 9" is still good because I drive the truck on occasion (carefully) up a steep gravel drive and the difference between the LS and non-LS is very noticeable.

If I try to combine the two trucks, there will be a whole lot of swapping going on; 302 out, 351W in, M5OD out, C-6 in. So swapping the the rear axle and the hubs on the front would just be another step in the process.

If I could weld, I would just fix the frame on the F-150 myself but I can't, so to have it done I have to pay someone and money isn't something I can throw around. Making swaps that don't require fabrication skills I think I can do.

 

sounds like a great project to learn how to weld. . .if you can competently (and i emphasize "competently") wield a wrench, you can wield a mig welder. its really not hard. . .110 mig welders are all over craigslist in my area, i can only imagine you can find one in driving distance. 110 is a perfect unit to learn on and wont break the bank. the only way to learn how to do it, is to do it. classes (im assuming classes would be the only "other" way to learn???????) are for people who don't know what they want to do, but want to do something.

 

I'd NEVER use a 110V unit for frame work....


I'm not even gonna touch the whole 1/2 ton axle swap into a 3/4-ton truck

 

a high duty cycle 110 welder will be fine for his 3/16 frame. optimal? no. cheaper? absolutely. capable of penetrating 3/16? definitely. i took all that into account when i suggested it. afterall, he's not building something from scratch.

my 110 is dusty, but that's because i have 220 mig, tig, and heli-arc at my disposal.

as for the axles, its not like he is at risk of blowing either up regardless of his low power configuration unless he's doing something stupid.

 

Thanks for all the input, guys. If I make this swap I won't be doing anything stupid. This truck is for hunting, occasional light hauling and bad weather transport, all of which will be pretty slow speed activities.

 

If there is a community college in your area, check with them to see if they offer welding classes. If they do, you may be able to get one of the students to take on your truck and save lotsa moolah.