Front axle toast ! 97 F250 Crew 4wd 7.3l
 

Goin down the mountain yesterday on ice and boom front axle pops out of gear housing.
Twisted off the drive shaft into the gear housing and screached to a halt.
Checked the gear oil on the axles this summer and it obviously leaked out ... bone dry with no sign of leakage.

Even the bearings are "welded" onto the shaft.

Read posts here and trying to figuire out what to do.

Local shop will put a used axle in complete for $1500 with 90 day warranty.

Or do I go plan B and do it myself?

Have a couple neighbors who will help for $200 who have done this before (semi-retired mechanics)

The shop used the VIN of the vehicle to determine the type of axle on the truck.

What stock axle is in there now?

Why is going to a DANA 60 better? Just more duty one ton rated?

What do I need to ask / do to get the right axle from a salvage yard?

Called a salvage parts supplier and wants $850 for the axle with only the gears nothing on the ends (brakes , steering , springs ... etc.)

If I do it myself I am at at least $1100 plus I would put on new rotors / pads. Steering linkage is a couple years old. (30,000 miles)

Tag on rear axle s 132 n
L10 10 2 6M16

4.10 gear ratio?

I would do a Dana 60. It is easy. Solid axle just bolt it up. You obviously will need to get another driveshaft too. or get one from a F-350 and get the yolk from the front of the trans case to go with the driveshaft.
A D50 replacement will be cheaper though and will most likely ride smoother but that is up to you. Look for someone putting in a D60 and get their old axle.

i would put a Dana 60 solid axle in it and never look back.

you are missing some of the tag info, but yes, you have 4.10 gears with a limited slip differential in it now.

Rear tag probably originally said "4L10....", but the hole to hang it went through the "4". Or the 4 is behind the bolt head.

That's a lot of money for another TTB. Since you have to spend some money, may as well see this as a golden opportunity, and go Dana 60 as said. It's not so much the 60 vs. 50, but the solid axle vs. TTB, that's the big advantage. Less trouble-prone and easier to keep aligned, and rides better. Easier to maintain; time to change the diff fluid? Just like a rear, pull the cover, drain, gasket, refill. On a TTB, the "cover" is integral with the beam, and a simple fluid change is a major PITA.

My rsk equipped f350 rides great.have had tt before.i would spend no money to fix that heap

I checked the fluid by unscrewing the drain plug but never checked the level. Very poor technique.

What do I ask for when locating a Dana 60?

What years are compatible? Just look at a F350 with any engine and 4WD?

Any year from 80-97 will bolt right in. you need to look for a 1 ton 4x4, NON dually. Any engine/trans combo will work although the drive shafts might be different.

Diesel Rod

Truck has 4.10 gears on it now with a manual 5 speed.

Typically pull a trailer wieghing under 6000 pounds.

Would it be best to upgrade the entire sus pension and get front 60 and rear 80 with

3.73 gears???

For better fuel economy?

Run stock tires and stock suspension.

I will dissagree with diesel Rod. 85.5-97 is the years you want a Dana 60 from. 80-85.5 was aD50 TTB in f350s

a dually axle WILL work for you, you would just need the outer hub from your D50 TTB. then you could sell the dually hubs and recoup some of your money

Ok AGAIN(we should really make this a sticky

85.5-91 Dana 60 king pin with pin on calipers
92-94 Dana 60 ball joint with pin on calipers
95-97 Dana 60 ball joint with Bolt on calipers(slightly larger brakes from the pin on style)
ALL listed above will bolt right in your truck. It makes things easier if you find the pin on/bolt brakes on style to match yours.

Track bar mount(bolts right where the old TTB bracket went on the back of the crossmember), also will want a track bar

F350 Springs are a MUST if you want to retain ANY ride. The F350 springs have a LOWER spring rating than the F250 springs do and will give a MUCH better ride.

Driver side U-bolt plate. You need this to properly clamp the leaf slings to the axle. This is COMMONLY OVERLOOKED and they are VERY hard to find separately and typically got for 125-150. IF you cannot locate one you NEED to CUT into the webbing on your pumpkin and mount the U-bolts upside down. You will also need to make a new top spring bracket to accommodate the new setup.

Steering linkage F250 steering linkage is different than F350, so you need F350 linkage. ALSO the pitman arm is LONGER on the F350 so you will need that as well.

Front driveshaft The F350 uses a double cardian shaft. They use this because in a f350 the angle is more severe and the F250 will bind. Some have said they have used the F250 shaft, but They must not feel the vibration a@50mph. The front drive shafts vary in length by which trans you have, but you can get any variation and just get it retubed for your needs. A LONG with the F350 driveshaft , you NEED the CORRECT f350 yolk(special yolk for double cardian shaft)92-95 used a BW 1356 t-case and in 96/97 a BW 4407. the yolks are NOT interchangeable, you need a 1356 yolk for a 1356 t-case and a 4407 yolk for a 4407 t-case.

Shocks are the same length

Front brake hoses can be reused, but will need to be slightly bent, OR just Get F350 ones

Couple things . You will need the same gear ratio as the rear axle. They came in 4.10 and 3.54

For the truck to sit level, a F350(4") rear block will be needed for the rear

The Dana 50 outer Knuckles are Not interchangeable with the D60

Rear axles are all Sterling 10.25 in F250/f350

I have done this swap so many times, I have it down to a 4hour procedure, but for 1st times, plan on a weekend

Did not know that, learn something everyday. Brad I sent ya a PM, had some D60 questions for ya.

Diesel Rod

Wow thank you so much.

Do you know a shop specializing in having this setup experience?

The explanations are so complete. Probably will take a weekend to complete ... probably more for my first time.

Did a local quick search on Craigslist and seems the best price for a used front Dana 60 is $1200 and it is not complete. Ouch !

Found front/rear 2005 F350 Stock Axles off a 2005 Ford F-350 Super Duty 4x4 all for a grand.

3.73 Gearing

Front Axle is set up for coil springs.

Front Axle: Dana 60
Rear Axle: Sterling 10.5

What do you think ... not gonna match up?

Where are you brown? I have 2

I live near Los Angeles.

Good luck......