95 F350 Frame Swap to 96 F-Superduty.

[Dirtleg]

I guess I am starting a build thread.

Backstory. About 7 weeks ago I picked up a 95 F350 Dump truck. Had some squirrel damage under the hood and after fixing some wiring and replacing the IDM I got it running.

Immediately after that I had battery cable issues causing a no crank condition. Truck is very rusty so grounds are sketchy. Messed around and got it starting good again. Still haven't replaced cables because of what comes next.

I started thinking about all the bodywork and frame work it would require to make the truck nice and I decided no way, I'll just leave it as a beater.
But then a rust free 96 F-Superduty rolling chassis complete with axles, brake lines, steering gear, hydroboost and pump plus all hoses, both fuel tanks and even the exhaust from a 7.3 was still attached dropped into my lap for cheapish. Same wheelbase even. Couldn't say no to that.

And 1 day later a rust free cab popped up 1 1/2 miles from my place for $300. Came with everything minus the doors. Gauges, HVAC, seats, rubber mat steering column etc etc. Also a rust free hood.

So now I am going to make a nice dump truck out of all these parts.

Pictures.
Truck

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Cab

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Frame.

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And I found this on the axle. Obviously for ride height. Anyone seen this on an F-Superduty?

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[lotzagoodstuff]

And I found this on the axle. Obviously for ride height. Anyone seen this on an F-Superduty?

Usually you see a ride height control valve on something with air bag suspension (very popular on motorhomes for instance). It's interesting that it's on a Superduty F350 chassis, makes me wonder if that axle might have come out of something else but it sure looks like it was born there. Maybe a "max recommended squat/max load" sensor?

In any case, sometimes when you least expect or need it, you can be blessed with some stuff falling into your lap. I just acquired a new to me two wheeler while just casually minding my own business when something I couldn't pass up presented itself to me. Fate, destiny, blessing: you choose based on whatever you believe or don't believe in, but IMNSHO it looks like you have an awesome opportunity to build a PSD Superduty dump, which is a really handy rig to have in your fleet . My only fear is that you'll make it too nice to use as a functional dump truck, but that coming from a guy who likes work trucks rough and ugly. Nothing wrong with a pretty truck, but when it's got a dump bed on it, I think it should look similar to an old wheelbarrow

 

[Dirtleg]

Usually you see a ride height control valve on something with air bag suspension (very popular on motorhomes for instance). It's interesting that it's on a Superduty F350 chassis, makes me wonder if that axle might have come out of something else but it sure looks like it was born there. Maybe a "max recommended squat/max load" sensor?

In any case, sometimes when you least expect or need it, you can be blessed with some stuff falling into your lap. I just acquired a new to me two wheeler while just casually minding my own business when something I couldn't pass up presented itself to me. Fate, destiny, blessing: you choose based on whatever you believe or don't believe in, but IMNSHO it looks like you have an awesome opportunity to build a PSD Superduty dump, which is a really handy rig to have in your fleet . My only fear is that you'll make it too nice to use as a functional dump truck, but that coming from a guy who likes work trucks rough and ugly. Nothing wrong with a pretty truck, but when it's got a dump bed on it, I think it should look similar to an old wheelbarrow

I hear you on the old wheelbarrow mentality. For this reason paint will be tractor paint, not automotive. I want it to look decent, be protected from the elements, comfortable (within context) and reliable.

Effectively lose all the rust, keep it from rusting again, and use it regularly.

I need it so I don't have to drive the Skid steer all over 1 bucket at a time as I am moving what will probably end up around 1000 yards of dirt before I am finished. So it has to be a quick frame swap. No time for a nut and bolt restoration.

 

[lotzagoodstuff]

1000 yards of dirt: you need a cheap triaxle

 

[Dirtleg]

1000 yards of dirt: you need a cheap triaxle

Would love one. But my property is tight and steep. No room for anything bigger than what I have. 4wd was not an option it was a necessity. Plus my excavator and skid steer are not going to fill a tri axle efficiently. They are also on the small side. Work with what you got. No one is paying me so it's just my time.

 

[TheRadBaron]

And I found this on the axle. Obviously for ride height. Anyone seen this on an F-Superduty?

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I had an ‘89 F-SuperDuty chassis and it had this device on the rear axle, too. I assumed it was for a rear wheel ABS system but I never looked into it too much.
These kind of devices are common on older trucks with rear ABS.

 

[KansasIDI]

@Dirtleg
That assembly is to increase brake fluid volume to the rear calipers, these F-Supers have disk brakes all the way around. As you increase axle load, brake fluid volume and pressure is increased.

 

[KansasIDI]

F-Supers don’t have ABS, for the record.

 

[KansasIDI]

Are you planning on using the F-Super rear axle with a Dana 60 front? If so, let me introduce you to two complications.

While the Dana 60 will bolt right onto the F-Super frame, it will not have the same gearing as the factory Dana 80 rear the F-Super has.

The Dana 60 likely has 4.10s, 3.55 also would have been an option but not common at all with cab and chassis trucks.

The Dana 80 has either 4.63, 5.13, or the much rarer 4.30 limited slip. There are 4.10 gears available for the Dana 80 that you could swap in. Alternatively, 5.13 and 4.30 gearsets are available for the Dana 60 front. 4.63s are not. I will note, most F-Supers have 5.13s

The Dana 80 rear in this application has no parking brake system, as it is on the driveline bolted to the back of the transmission on the F-Supers. If you are using an automatic transmission, then that shouldn’t be much of a problem.

Of course, a custom rear driveline will need to be made, as the pinion length on the Dana 80 differs from the Sterling axle on F350s. The U joint is also larger on the Dana 80. The factory front driveline from the F350 should work just fine.

Best of luck, I have considered building a 4WD F-Superduty myself and have most of the parts I need to do so. I’ll be interested to see how this turns out.

 

[Dirtleg]

@Dirtleg
That assembly is to increase brake fluid volume to the rear calipers, these F-Supers have disk brakes all the way around. As you increase axle load, brake fluid volume and pressure is increased.

Awesome. Thank you for that. I really haven't looked at it too much at this time.

Makes sense that you would want more braking force on the rear as the load went up.
At least now I know what it's for and to make sure to take care of it (As in not destroy) during the swap process.

 

[Dirtleg]

Are you planning on using the F-Super rear axle with a Dana 60 front? If so, let me introduce you to two complications.

While the Dana 60 will bolt right onto the F-Super frame, it will not have the same gearing as the factory Dana 80 rear the F-Super has.

The Dana 60 likely has 4.10s, 3.55 also would have been an option but not common at all with cab and chassis trucks.

The Dana 80 has either 4.63, 5.13, or the much rarer 4.30 limited slip. There are 4.10 gears available for the Dana 80 that you could swap in. Alternatively, 5.13 and 4.30 gearsets are available for the Dana 60 front. 4.63s are not. I will note, most F-Supers have 5.13s

The Dana 80 rear in this application has no parking brake system, as it is on the driveline bolted to the back of the transmission on the F-Supers. If you are using an automatic transmission, then that shouldn’t be much of a problem.

Of course, a custom rear driveline will need to be made, as the pinion length on the Dana 80 differs from the Sterling axle on F350s. The U joint is also larger on the Dana 80. The factory front driveline from the F350 should work just fine.

Best of luck, I have considered building a 4WD F-Superduty myself and have most of the parts I need to do so. I’ll be interested to see how this turns out.

So in response to your comments, I am initially doing an axle swap at both ends. I do plan to re-gear the Dana 80 to 4.10 to match the Dana 60 and re-install at some point. Not a high priority ATM.

I am stuck with the E4OD it seems as every time I attempt to acquire a manual swap, something goes sideways. After a decade of this I'm tired and don't care anymore.

That said when the Dana 80 goes back in I will have a parking brake on it. I might know where a factory one is. Or I will fab something up. Not sure yet.

I will say after looking at all the cobbled/butchered wiring under the dash I am looking forward to having the opportunity to clean it all up properly.

 

[KansasIDI]

So in response to your comments, I am initially doing an axle swap at both ends. I do plan to re-gear the Dana 80 to 4.10 to match the Dana 60 and re-install at some point. Not a high priority ATM.

I am stuck with the E4OD it seems as every time I attempt to acquire a manual swap, something goes sideways. After a decade of this I'm tired and don't care anymore.

That said when the Dana 80 goes back in I will have a parking brake on it. I might know where a factory one is. Or I will fab something up. Not sure yet.

I will say after looking at all the cobbled/butchered wiring under the dash I am looking forward to having the opportunity to clean it all up properly.

Adding a parking brake to the rear axle is a good idea, I will be interested to see how you do it.

 

[Double-S-Diesel]

Would it just be possible to use the rear from the f350. then you would retain park brake function.
and that would solve gearing issues.
with the e4od do you even need the park brake ?

 

[KansasIDI]

Would it just be possible to use the rear from the f350. then you would retain park brake function.
and that would solve gearing issues.
with the e4od do you even need the park brake ?

That’s my point on the statement I made regarding having an auto transmission with a 4WD swapped F-Super that would retain the Dana 80, since you have park in the transmission you could probably get away with no e brake… not sure on the legality of that though.

You could swap the Sterling 10.25 in place of the Dana 80, and it sounds like that is @Dirtleg ’s plan, at least for the moment. I must also point out that the spring hangers aren’t the same, the F-Supers use wide leaf springs and huge cast hangers, whereas the F350 cab and chassis trucks use narrow leaf springs with much smaller stamped hangers. You may have to drill a few holes in the frame, not sure on mounting spacing with the F-Superduty vs F350 C&C leaf springs hangers. Also, the F-Superduty frame itself is much thicker and heavier than the F350 version. There is a reason these F-Supers have a higher GVW and much lower gearing, they are built to handle the extra weight.

 

[u2slow]

I am stuck with the E4OD it seems as every time I attempt to acquire a manual swap, something goes sideways. After a decade of this I'm tired and don't care anymore.

That said when the Dana 80 goes back in I will have a parking brake on it. I might know where a factory one is. Or I will fab something up. Not sure yet.

I here to warn you the E4OD is disappointing and may well re-ignite your caring. That was the case for me having had a PSD/ZF5 first, and a PSD E350 second.

There's no factory parking brake that bolts onto this Dana 80. The housing ends are different for 99+. I have seen a custom pinion brake done before though.