2005 super duty axles into 67

[67fordtruck]

Quick question, anybody done this axle/front coil swap? I have not delved into this to far, but there has been a set of 2005 super duty axles (D60 front, sterling 10.25 rear) on craigslist for awhile. My thought process is swapping the axles into my 2wd 67 crew. I need to measure to see what the difference in frame widths are between the two, and also look at the steering setup possibilities. I always prefer to go leaf sprung, but the turn radius gain and strength of the kingpin front and heavy rear is pretty appealing. It would be a big bonus if 3.50ish gears were in.

So my question, anybody done this to a bump, or heard of it done?

[DCrusher]

This just my opinion. Why? the task your taking on is massive I'm not trying to discourage you but really look at it your taking a 2WD truck and wanting to make a 4WD. I would look for another 4WD truck and take the frontend out of it with frame and transmission, tranfer case that way you have a template for all the stuff and have all the stuff or find another crew 4WD frame or whole truck and buy it. This is just my opinion.

Quick question, anybody done this axle/front coil swap? I have not delved into this to far, but there has been a set of 2005 super duty axles (D60 front, sterling 10.25 rear) on craigslist for awhile. My thought process is swapping the axles into my 2wd 67 crew. I need to measure to see what the difference in frame widths are between the two, and also look at the steering setup possibilities. I always prefer to go leaf sprung, but the turn radius gain and strength of the kingpin front and heavy rear is pretty appealing. It would be a big bonus if 3.50ish gears were in.

So my question, anybody done this to a bump, or heard of it done?

[70shortwide]

4x4 crews arent just lying around... If he has a longbed crew he would be building a truck that was never offered... This is a way for him to have something you wont ever have...

[Alstoyz]

I'm dig'n the idea!!! However, I think the '05 front Dana 60 is a ball joint rather than kingpin axle.?.?

[KnockKnock]

zakt did a 4wd conversion on his crew. He's got a lot of good info posted on how he did it with the help of a donor truck.

[averagef250]

The axles have Metric lug patterns so you will have to run 99+ superduty wheels.

As was mentioned, the front is a balljoint axle, not kingpin.

The rear is a Sterling 10.5, not a 10.25.

Most have 3.73 or 4.30 gears.

Personally, the only way I would do it would be to put your entire crew body on the late model frame with axles and suspension already done. Use the entire brake system from the newer truck, the wheels and tires, etc, etc. If you try to connect those axles to your old frame you're in for a lot of work, very custom stuff and it would be a lot less work with a better end result to just use the whole late model frame and spend the time changing it's length to fit your body and building new body mounts.

Those axles are worth less than dirt. Nobody is buying them because they only fit Superduties and have the Metric lugs.

Probably the number one reason I would never take one of those front axles if someone gave one to me is the unit bearings. I've had awful experiences with unit bearings in newer trucks. They don't give you much warning before they come apart and when they do, your stuck, you cannot keep driving the truck. Old tapered spindle bearings last as long or a lot longer with proper maintenance and they don't fail spectacularly right when you least expect it. You can rebuild the old style spindles many times for what the unit bearings cost.

There are several companies selling retrofit hub systems for Superduties and Dodges and they sell a lot of them because folks hate the unit bearings.

If you don't want to shell out the bucks for a 78-79 HP60 a reasonable option if you are a good fabricator would be an 85-91 HP kingpin 60 on superduty or highboy leaf springs, 78-79 F-250 steering box and whatever rear axle you choose. You can offset the spring hangers outside the frame for the newer axle spring spacing. You have to make that stuff anyways, your truck's a 2wd.

[Alstoyz]

I'm in the process of putting my '72 CrewCab long on a '93 F-350 4x4 CrewCab chassis. I had to shorten the frame 5" right below the cab. It should be pretty straight forward...

[67fordtruck]

Hmm, lots of great info here! Thanks guys!

I am not opposed to the fab work to get it in there. I am kicking myself for missing out on a F-350 short bed crew frame, 69 I think a few months ago, but in the grand scheme of things I want an updated suspension anyway.

I was under the impression that 05 had a kingpin front end, but regardless in my experience I have got a lot of miles out of balljoints.

As far as unit bearings, I am really not a fan. I was unaware they make a conversion kit for those though, so that is pretty killer.

The biggest downer though for using the 78/79 D-60 aside from owners being very proud of them ($) is the lack of turning radius. I have also toyed with the thought of retrofitting the entire suspension from a later model diesel dodge, but again have not actually put a tape on the frame to form a plan.

The grand plan is to save up for a few months and buy the donor dodge diesel by the end of this year. Once that happens, Ill pull the crew in the shop and start the 4wd conversion and start working on body work while the diesel is the daily.

Anyway, thanks again for the responses. Keep them coming!

[smokey3215]

I made a 2wd crew into 4wd all I have to say is its a lot of work. Is it worth it hell yea because I can say I built it. So if you have a lot of money and some time go for it.

[averagef250]

There have been 4 78-79 HP60 front ends for sale on Portland Craigslist in the last 6 weeks between $900 and $1200. All the while a really smart fellow advertises one in the same shape for $1800.

You're looking at a huge undertaking. I'd urge you to get a well thought out plan together before you jump into it.

The hard part of putting a 5.9 into an early Ford is you have to do engine, transmission, frame, steering, front suspension, intercooler all at the same time. There's no keep it in one piece and driveable. If you use a Dodge frame and axles go as new as possible. The 2002 and older chassis are awful. They have a rear axle Dodge wants you to believe is a Dana 80, other than that they are pretty poor.

[smokey3215]

^what he said all or nothing it took me a year to have mine movable that's the word. And I bet I am at 10,000.00 if not more to get it to that state (scared to look at recipets ).

[averagef250]

As far as unit bearings, I am really not a fan. I was unaware they make a conversion kit for those though, so that is pretty killer.

Worth mentioning that the conversion kits cost more than buying a couple HP Dana 60's, so the unit bearing axles really aren't a good option if you can avoid it.

Might sound over the top, but after weighing all the options, years of planning and quite a number of Cummins swaps into early Fords I'm building the frame from scratch from rect tube for my '70. I'm using the 78 HP60 because I have it, Superduty leaf springs front, probably 78-79 steering box, but may go 80-97 box. Dana 70 rear on highboy springs for now.

The frame rails are parallel, straightforward to align, new tubing is clean and cheap and I figure I can build a new frame a heck of alot faster than I can prep an old one for reuse. There's another reason for me going to the fabbed frame, but it's not related to the Cummins swap.

I will be building atleast one crew frame as well. I was thinking about building a jig and offering the frames all setup to receive an early Ford body and a Cummins engine/dodge trans. If I were to market them I'd set them up for 85-97 HP60 front axles, superduty leafs. Go for the parts that are proven, available and make a good finished product.

[fordguy_78]

There are plenty of guys that run the 05 on up sd axles. The 05 and up axles have a bigger unit bearing than the prier years they also have bigger better brakes and yes they are ball joint. here this guy might have some pointers for http://www.pirate4x4.com/forum/ford/998 ... -tons.html There are also a bunch of sd axle swaps on full size bronco in the sas section http://fullsizebronco.com/forum/forumdisplay.php?f=29. I personally would not have a problem running 05 up sd axles if I had not found my 88 king pin 60 for what i did.

[67fordtruck]

Average250, that is an interesting thought building a frame from scratch. In looking at it, it does not seem to be a ton more work than modifying the old one. I have been planning to build a new frame for my 75 cj5 one of these years.

Anyway, my neighbor came by today and we took a few measurements. The 05 F-250 is 38" outside frame rail to outside frame rail. My 67 is 34". This to me seems doable. I forgot to take a look at the steering gear setup on his truck though.

Anyway, I am still in the research options phase. Ultimately I am looking for a combo of tight turning radius and strong axles and a well balanced suspension.

[fordguy_78]

there's always what this guy did he is running a sd frame and fire wall. http://www.8-lug.com/features/ford/1004 ... ford_f250/