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I am looking into swapping Rockwell 2.5 ton axles onto my 1978 F-150. I have more time than money, so before I buy I would like to hear if anyone has done this, and their reactions. It is either going to be rockwells, or Dana 60s.
For ease, the danas would be easier as the rear would just fit. I would love to slip a set of rockwells under my truck, but only if I had 49s to put under it. What size tires do you plan on running? Anything less than 44s aren't hardly worth it, in my opinion.
The advantages to deuces that I see are the top loader, hi ground clearance, and brute strength. The problem I see is the front axle, and setting up the steering. Also since my truck has coils up front, I might need to change to springs to facilitate an easy sway. I've never done, that and I don't know if it is difficult or not. Let me know if you think I'm barking up the wrong tree.
A couple of other things to consider with Rockwells:
1) You will need a LOT of lift. The center section is really tall and the drive shafts enter the flange on the worm/pinion gear at something like 10" above the axle shaft centerline. That means that you have to have enough lift over that front axle to keep from putting that tall 3rd member into your oil pan, or the rear into your gas tank.
2) The front diff is centered. If you want passenger's or driver's side drop you can get it if you're going to shorten the housing anyway and get new shafts. But that's money and specialized parts to buy.
I'd do it, though, if I were you! Ditch the drum brakes, go with a pinion-mounted single disk on each axle and have an impressive machine!