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I am not sure about the TTB mounting spots. I think the TTB is the same on both except one is a D44 and the other should be D50. I know the 3rd members are interchangable, but , I dont know if the actual beams themselves are different. The axle shafts are interchangable also except what you have from the knuckle out will make the difference. IOW the spindles , ball joints, rotors calipers and the like will be different between the two.
If I'm not mistaken, the pivot brackets on an F250 mount differently than the ones on an F150 or Bronco. We also need to remember that F250 front axles are leaf sprung, so F250+ frames do not have the coil spring towers like an F150 or Bronco. You will need to add these if you wish to retain your D44.
Also, if I'm not mistaken, the majority of F250's came with D44 HD's, which were similar to the D50, but still had their differences. It was the 80-85 F350's that came with D50's, before Ford went back to solid D60's.
My 96 and 97 came with the D50 TTB. I wasnt for sure if all of the F 250's equipped with the TTb were leafs. Both of mine are and are 7.3 DI's, but , I couldnt remember if Ford swapped back and forth on those due to the weight of the diesel motors or not. Supposedly the inverted arch of the front leafs was supposed to help with travel.
No, as I said before, the f250 is a different animal. Nothing from the f150 suspension will fit. The frame is different, the ttb is different, nothing is swappable. Are the beams the same? No, not even close. Your only option if you get a f250 4x4 is to put your f150 cab on the f250 frame. And the engine/tranny/transfer case will bolt in. That's it.
About making/fabbing crossmembers and mounts. Anything can be done and swapped if you have the time and the skills necessary to do it. But there is really no purpose in re-inventing the wheel. Ford already made the combo that works, all you have to do is find it and bolt it in. There is no purpose in fabricating and installing brackets to put f150 parts onto a f250 frame. Just buy a 2wd or 4wd f150 from 1980-thru 1996, and use that frame. Everything will bolt on.