95 PSD Front axle swap
 

I have had this 95 psd 4x4 for about 6k miles. It had brand new yokohama tires on it when I bought it, and it is wearing the outside edges of the tires faster than I can rotate them. Now it seems like the alignment is way out, but I have found that the ttb front end is weak. When I back up the front tires will literally bow inwards (-camber) about 8-10 degrees, and when I drive forward they bow out, and that is what is wearing out my front tires so fast.

Now I am looking for a Dana 60 front axle to install in place of the ttb.

Has anyone attempted this before, and does anyone have a dana 60 laying around for sale. I should mention I am only looking for a stock axle from a 1 ton ford.

good luck finding one around here to answer your? yes it is done all the time just search dana 60 swap you will find it all

Here's a good write up I found in a quick search:
Dana 60 Conversion for F-250 years 1986-1996 .: Articles
Just like bigbadwolfe said, yes its been done plenty of times but the D60 usually goes with a nice price tag.

Be prepared to spend $1000 or more for the axle and parts needed for the swap. I recently sold one for $1000 and had 3 guys waiting in line in case the first backed out. Oh yeah that was before the $400 freight bill. $1400 total

The rotation of the tires is due to weak radius arm brackets and bushings in the 150's, I cannot recall if the 250's have them however.
.... I'd go look at the farm truck, but its gone at the moment.

The swap is expensive.
I'm thinking about hording axles just to make some resale money.
With possibly rebuilding them before sale.

If your TTB is eating tires it's probably your ball joints.
For the D60 swap you need the complete axle hub to hub (brakes included), track bar, track bar mount bracket, springs, and all the steering linkage parts to make the swap.