'71 "F200" SWB PROJECT

[sargentrs]

So this is a quick pic I took of the shackle issue I'm having with the rear leaf spring hanger.

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It's hard to tell in the pic, but the "inboard" side is not going down far enough to let me slide the bolt in. The flange on the poly bushing is hitting the bottom of the hanger where it starts to curve out.

I had the same problem when I did mine. I just started the bolt in the outside hole and put a C-clamp on the spring eye/shackle, close to the inside. Ease the C-clamp tight, compressing that inner corner and the bolt will tap right through.

[mc33212]

Thanks Randy for the advice, I did see your build thread where you talked about. I tried it quickly last night and looked like I was able to put the bolt through. I'll give it a final go this weekend.

[mc33212]

Last night I also spent some time putting together my "new" welder. Got the famous $30 welding cart from Harbor Freight and got it all setup. I just need to pickup a gas tank, but I may practice with the spool of innershield wire first.

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The cart worked out well, but as always, the hardware was cheap as heck and the instructions were horrible. The back wheels actually wouldn't fit on the axle either. I wound up putting them in a vise and using a hand saw to shave about 1/8" off the thickness of the hub so I could get the cotter pin through the hole in the axle.

Oh, well......it works!

[Biblethumpncop]

Thanks 71Prerunner. I'm actually getting a bunch of my spare parts together to post some items in the classifieds and on craigslist/ebay. Just off the top of my head I've got a radiator, various side trim pieces, some 67-style headlight buckets, side hood reflectors, assorted hood letters, some headliner trim pieces, some heater controls, radio bezels, an original Philco AM radio, and various stock intrument clusters and bezels. I'm also probably going to sell off the long bed from my F250 CS. I thought about cutting it up for parts, but it's in pretty darn good shape, it's more useful to someone else that needs the whole thing. It's got a filler neck hole on the driver's side and the built in tool box on the passenger side.

I'll be collecting and taking pictures of all this stuff soon.

Did you ever list your bed? Mine's not horrible, but I may be interested in the bed and a tailgate if you have it still.

Thanks,
John

[mc33212]

Well, time sure flies when you move to a new house and get a new job. Time to get back to work on the truck and pick up where i left off.
Which was here....

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I got my F250 front suspension and twin piston caliper disc brakes in before I moved, then got to work on finding a rearend. I picked up a Dana70U at a junkyard from an 84 F250 and got to work cleaning it up.

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So of course, the advantage of a newer rearend is it's full width to match the front track, but has the wrong spring perch spacing. I was able to cutoff old perches, and get a new pair to fit the 3.5" diameter tubes and the narrower spring width and get the pinion angle set.

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I read in several places the pinion angle should be about 1.5-1.7 degrees down from the transmission output angle. So that's what I shot for with a digital angle finder.

[mc33212]

The next step was to attach them permanently. I've only welded a few times but I think I did okay. I don't think they'll fall off! But if they do I think I've gotten better at welding already, while i practiced filling in cuts on the axle tube...

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Overall it wasn't too bad, and nice to be over this hurdle. Next its off to the differential shop for some new bearings and machine work....

[mc33212]

So got the diff taken apart. Its a 4.10 PowrLok limited slip. You can see some broken pinion shims in the pic. Otherwise the gears and carrier seem in great shape.

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Bearing are lunched...

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And this was the biggest issue, the carrier bearings wore into the sides a bit. I read this was a common issue on Dana axles. I believe Sterlings have a shim on the outside to help prevent this from happening when the bearings start to die.

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I did find a local shop to machine the carrier bearing bores. So off it goes....

[mc33212]

In the meantime I wanted to replace the broken rear upper shock mounts. I decided to try these Dorman replacements for newer F-series trucks. I figured I'd have more shock options for the rear going to a bushing/sleeve mount, versus the stud mount.

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Looks like the holes are only slightly off. I hit the bracket with the die grinder and open up the holes a bit.

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Here is the final bracket installed.

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I'm still not 100% sure on the placement I chose for the lower mounts. But I guess i can always adjust later on once I have the truck back on its tires and I can test it out with a real shock.

[mc33212]

So, been busy over the last week getting my diff rebuilt. The Shaggin' Wagon was able to haul a full width axle pretty well. It's almost like I should get a truck.

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The shop was able to machine the bearing surfaces and install new bearings with some added shims. Apparently they used some other bearing caps as well, that were on the smaller side of the tolerance. Along with that of course, new pinion bearing and shims.

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And here's the end result with a quick coat of paint....

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Now I need to install new hard brake lines and start assembling the hubs...

[IN2FORD]

Awesome work!

Barry

[Wilfred of Ivanhoe]

Looking good!

[mc33212]

Okay, so got a bit more done on the truck these past few weeks....
Threw a final coat of paint on the axle and got the brake lines plumbed and the brake backing plates with wheel cylinders.

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It was a little bit tricky because I used pre-terminated brake lines from the auto parts store. I think the 20" line for the short side and the 50" for the long side. My brother has a flaring tool, but they were only longer by a few inches from the OE lines, I figured I could make up the distance with the bending.

So the axle is back in, hopefully for the last time! At least for now.

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I hadn't initially planned on new wheel bearings, but I figured I've come this far, I might as well have a COMPLETELY rebuilt rearend. So got new races into the hubs and pressed in new studs.

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[mc33212]

Okay, well the axle is finally in. Took me a minute to remember how the parking brake lever went back together, but luckily I have a Haynes manual for Ford trucks and the internet provided the rest.

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Quite bit different from when I pulled the axle from the junkyard....

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And finally back on all fours. At least that's what she said. Haha....

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Now I've just got to plumb the front brakes. I ordered a new booster/master from O'Reilly and UPS played kickball with it. The collar around the adjustable rod was broken. So I'm waiting on the replacement.

Also, based on a quick an dirty measurement, I need about an 1-1/2" more spring up front so that it's level. I may look for a suitable spring so I can get a bit more clearance for the 33s I'd like to install (285/75R16). Right now I've got some 31" rollers from my brother's Excursion (265/75R16).

But that'll be the battle for another day. Right now I just want the thing to move under its own power so I can take it to inspection and get it registered again.

[Lone Ranger]

That rear axle is a beast looks rear sharp too. You have a nice looking truck.

[mc33212]

Thanks! Yeah that axle is nice and beefy. I figured they're all the same price at the junkyard so might as well upgrade now instead of when I break something... Also, I really like how the full width axle looks in relation to the fenders. It's a bit odd, since I'm used to seeing these trucks tuck the rears more, but I think it may also give me enough room to go outboard on the shocks. We'll see. This was my first axle swap project so pretty proud of how far it's come along.

Here's a different view of it. The angle is funny, makes it look more raked than it is, but it gives a better shot of the side.

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