This is probably the hundredth time this queston has been asked, but there are too many threads to do a complete search. So, apologies in advance.

I'm the owner of a '90 F-350 Diesel Crew Cab 5-speed, 2-WD Dually w/ a standard (8-foot) bed. Now that my wife no longer pulls a horse trailer around, I really wish I had a 4x4 SRW w/ a short bed. But this truck has been ours since new and only has 49K miles on it, so I'm not going to sell it and buy what I want.

My thought is a three-step process: convert to 4x4, then convert to SRW and finally shorten the chassis/bed.

I understand the Dana 50 independent front axle from an early '80s truck is a bolt-on swap for my twin i-beam, coil-spring front end. Can anyone confirm this? Also, can I mount dually wheels on that until I get around to changing the rear axle?

Are there any transfer cases strong enough for a diesel that I can use with my 5-speed transmission? Without having to do major machine shop work, that is.

With regard to shortening, I figure the easiest and strongest way is to move the rear axle forward and chop off the extra at the back. However, the frame is flat on top but kicks up under the rear axle. If I lift the axle by the amount of the kick-up, can I move the axle forward without having a problem? (I'm going to lift both front and rear about 4 inches for the 4x4 conversion anyway.)

Finally, on the bed: did they offer a short bed in '90, or should I plan on shortening a standard bed?

Thanks in advance for responding.

 

You realize that simply selling the truck and buying what you want will be far less hassle/time consuming and probably cheaper in the end right??

That said, yes, Ford did make an F250 CrewCab Shortbed in '97, and possibly '96 as well. They are rare, and rarer still with a diesel and 4wd. If you find one, consider yourself blessed.

As an alternative, you may want to consider an F250 Supercab Longbed 4x4, which is about the same length as a CrewCab Shortbed and much easier to find. Or, if the truck is going to be your play toy and not a family transport vehicle, maybe just find an F350 RegularCab Longbed 4x4, which will already have everything you want, drivetrain-wise in the shortest available wheelbase length. These are not as common as F250 Longbed Reg Cabs and Supercabs, but much easier to find than a Supercab Shortbed F250 will be.

As for the transfer case, Ford used the BorgWarner 1356 part time transfer case in F250/350 trucks with all 3 engines (351, 460, and diesel) and with all 3 transmissions (C6, E4OD, and ZF 5-speed), in both single rear wheel trucks and duallies as well. The 1356 is available in manual shift and electric shift. It is an aluminum case, chain drive t-case with a descent low range gear in it.

On the front axle swap, since your truck is a one-ton, you may as well go with the monobeam Dana 60 front axle used in F350 4x4 trucks, both single wheel and dually. It is stronger and has fewer parts to wear out, and the truck can be lifted without the camber/caster issues associated with lifting an independent front axle, like the TTB Dana 50 used in F250's. The Dana 60 straight axle swap on F250's is a popular swap among the hardore offroad crowd and you can read several discussions on the subject by searching through the topics up in the Offroad forum.

As for the frame shortening, you're much better off to leave the axle mounted to the rear part of the frame and chop a section out of the middle of the frame instead.

Good luck with the project!