Hi folks!

I've seen this done on other forums and looking for advice and issues I should be concerned about.

I have a 1996 F250 extended cab 2wd 7.3 diesel in great condition. I like the OBS look. But in snow and mud, I need 4x4. I like the idea of a somewhat unique truck and would like to update the 96 with newer 4x4 drivetrain using a 2005+ donor truck.

I have found a 2006 F250 extended cab 4x4 V10 with blown engine for $800.

I'd be planning to swap both axles, suspension, driveshafts from 06 to the 96. This way the axle ratios and wheel hub/lug patterns will be matched. I'll gain rear disc brakes; better suspension and ride according to others; coil spring front has better turning radius vs a leaf spring front; nicer, bigger, newer wheels (hopefully they are nice or will have to find some).


1) I've read that the super duty has wider frame than OBS
-- so will need to move axle mounting brackets outward front and back?
2) 7.3 engine vs V10 weight
-- Is 05 V10 front axle and suspension strong enough for 7.3
3) Transfer case, a manual version for the 96 transmission
-- cut a hole in the transmission tunnel for floor shifter
-- bolt on the transfer case
-- cross-brace for transfer case
-- other parts or issues for this step?
4) Rear driveshaft, from 96 transfer case to 05 rear axle
-- Will it be difficult and expensive to get proper length and u-joints or?
-- Can I use 96 and cut down? Or 05 somehow?
-- Other issues?
5) Front driveshaft, from 96 transfer case to of front axle
-- Will the 05 front driveshaft fit?
6) Steering linkage
-- I've read this could be a difficult connection and may need a different pitman arm?
-- Other issues
7) Front Suspension connections, what needs to be done?
-- spring buckets, existing 96 useable?
-- radius arms mounting, ??
-- other issues?
8) Back Suspension connections - what needs to be done?
-- Leaf spring mounts on truck ?
-- Leaf spring mounts on axle ?
-- Shock connections?

Thanks in advance for any advice and help!