I am buying a 97 f-250 4×4 5 speed next week that was slightly wreaked. The front axle is bent and since I hate ttb axles anyways I figured I would throw a d60 under. I have never done this swap but I hear I is pretty simple. My biggest question. Are the leaf springs different? Are the drive shafts different? Are there any tricks that make this swap easier? Any other tips or suggestions greatly appreciated

 

The leaf springs are different load ratings I believe but will bolt up the drive shafts are different. My f250 shaft bolted in but it's not ideal since it doesn't have the double Cardon joint in it. I'm in the process of getting a flange for the t case and a 1350 yoke for the d60 so I can use a super duty shaft

 

What ark redneck said about the yoke and drive shaft.

Swap over the F350 pitman arm otherwise your U turn ability will be reduced.

Leaf springs are different, the F250 springs are stiffer due to the TTB. Replace them with the F350 springs. Replace your spring and pivot bushings now while it is easy.

Prep work items like longer brake lines, sourcing your replacement (if needed) F350 tie rods, collecting needed hardware for the track bar bracket, new U bolts, and servicing of the D60 hubs are all good time savers before swap day.

There are a number of pictures in the thread in my signature file that may be of some use.

Good luck!

 

Great write up on the d60 I will be using it for sure. The truck I am getting already has a 4 inch straight pipe and air intake. What would you guys say the next best thing is to do to help wake up the motor, bigger injectors, bigger turbo, ect ect......

 

Gauges and a tuner. Injectors and hpop if you need more

 

pretty much rite on track, except for the tie rods if needed comment.
use the complete F-350 steering components. they are different from the TTB stuff used on the F-250.

 

Since I am not having any luck finding a d60 for a reasonable price I am thinking of rebuilding the d50 for now. The left portion of the axle is bent and needs replaced. I found an axle housing that contains the difference cover. I have never rebuilt one of these before, is it pretty straight forward bolt together setup. It seems like the last time I took one out (about 4 years ago) there was something that was confusing, or different to work one. Any good tips for replacing the driver side of the d50

 

Maybe you can find a complete Dana 50 to swap in might be easier

 

I have not been able to find one of those either. I agree that would be easiest but I need to get this thing going, it is snowing right now and all my work will be done in the driveway

 

I was a little fuzzy with my words..... If the donor F350 tie rods need replacing, find the parts. If they are in good shape, this may not be needed.

Thanks for keeping things clear!