ok guys i did a d60 swap a few weeks a go, and am trying to finish up 5 speed swap now, i have to have a back short shaft made 5in longer and wanted to see can i still use f250 front drive shaft or do i need to use the one from the doner 350?? in the trany swap i was able to keed the 96 transfer case, and the 93 350 font shaft is a little diff from 96 250 shaft, o 93 is an auto as well, thanks just wanted to see if i need 2 shafts made

 

the 80-95 use a BW1356 t-case
the 96-97 use a 4407 t-case
the F250 front shaft is longer than a F350 but if you have some lift the F250 shaft should work
I prefer the f350 shaft because of the double cardian joint

hop that helps you some

 

Im about to hijack this thread!! Which rear driveshaft are you using??? the auto staft or the manual shaft????????

 

lol going to use my auto shaft as of now, useing my 96 transfer case, but i have to have 5in added to the short shaft, the shaft be for carrier barring, 85 bucks 2 get a new shaft, i think will no as soon as i have it in, your doner was an x cab right?? it should depend on what tcase you use your donner is the same year or 95 right?? my 93 and 93 have diffrent cases hope that helped some

 

Donor truck is a 93 x cab,,...all going into a 97 x cab...

 

ok so i no redman made a 1 in steel spacer, cause thats how much he was off, but his doner was a 95, so we have the same doner years, and they have diff transfercase than the 96, i am going 2 say you are going to be 5 in short as well , i put both tranys side by side and measered them out the auto is 5 in longeri think auto measered 32 in from starter hole to back of trany, manual was 27 in from starter hole to back of trany, transfercaseswas same 20 in, also if you look where your manual crossmember will be going its moved forward a few in not sure how much but i would say 5 in, the best thing i can say is do what iam doing get it all togater, slide short shaft from long shaft on rearend, take short shaft and mount carrier barring and measer how short you are i would say still 5 in, i will maybe no by the end of the day 2 day.

 

Jason as easy as it is to install and remove that front shaft you may as well just see if the one from the donor will bolt up once the trans and t case are in place. I don't know really anything though about Dana 60s. If it will not work then you can just have your original front DS shortened the proper amount.
I had a 95 ex cab donor for my 96 ex cab driver. I used the front shaft straight from the donor. It was slightly shorter to accomodate for the t case moving forward. I could have used the rear DS straight from the donor as well but I didn't. I'll explain. My original was in better shape. I measured and found out that the rear portion of the rear shafts were the exact same length between the two trucks. The difference was the front portion. I took the front portion off the donor shaft and put it onto my original. I wanted to keep my BW 4407 t case instead of using the donor's BW 1356 so I pulled the slip yoke of the front of my now fully assembled rear DS, bought a new u joint, and reassembled with the flange from the front of my original rear DS so as to mount up to my 4407.

When I completed the project the last thing I did was install the rear shaft which came up exactly 1" short. I put in a 1" steel spacer and bought some grade 8 bolts that were 1" longer than factory. Buttoned up beautifully and have had no balance/vibration issues to date.

I don't know where the 1" difference came from. My theory is 3 different possibilities: 1) The t cases are 1" different in length. 2) A rear DS from a manual with a BW 1356 is 1" off from a rear DS from a manual with a BW 4407. 3) The length of the output shafts are slightly different so the 4407's flange can bolt up flush with no xtra play although the 1356 can allow a small amount of play since it is a slip yoke.

Anyway, Kris with you doing a 4x4 ext cab -> 4x4 ext cab swap I expect you can do one of a few things. You can use the donor's t case and swap the front and rear driveshafts directly from donor to driver. You can use your 4407 t case and swap the donor's shafts directly but swap the end for the t case and add a spacer. Or if you want to keep the rear of your original shaft you can do what I did. Either way you should turn out fine.

 

Well so far ive put the pedals in and taken them out three times....The third time i had to take the clutch master off aswell....Ordered the Clutch fix right now..MAnn what a project hahaha but its fun.

 

Haha. At least you'll be quick with them when you have to do the clutch fix. Mine took a LONG time to come in but others, like William, said theirs came in a few days after ordering. I have to pull the brake master and the clutch master some when I take mine out too...

 

LOL everything going into this truck is new...And when i went to pop the clutch master rod onto the clutch the friggin bushing broke!! ERR so ebay'd a fix! See what happens

 

Well be glad you did! Think if it broke from putting it on how fast you're gonna blow through em by smashing it between metal with your foot. I went through THREE in THREE months. There was no fourth nor will there ever be

 

dude you still got more done than me!!! i spent all day working on my flywheel, and i got the pilot bushing in , thats it! dont get your fly wheel from a parts store get it from valair!! my oreily flywheel was off 400ths where it slides over the crank shaft! was a day with a lot of 4 letter words!i have it at a mecheran shop now getting fixed! going to try like hell 2 be up and running sat! o and i no on the pedals you get good after the 3 time or so! lol trust me