OK I just found a sweet deal on a 03 super duty dana 60 with 3:73 gears. I can get it for 300 bucks. My truck is a 92 2wd, too much work to make it 4x4 or sell and get a 4x4 then swap the axles?
2WD to 4WD has been done several times on here. The 03 stuff is coil spring right? Might talk to GregOH. He started down that road and then decided to go a different direction. His thread is just a couple below yours right now.
yours is 92 so i beleive you have the boxed frame horns. just bolt up the front shackle mounts, cut the coil bucket off and install the 4x4 shock mount, and hten mount the rear spring hangers. PMF or SKY have a brand new ready to roll front shackle reversal kit tha thas everythign you need to bolt up an axle under there, but its like 500 bucks.
Talked with a friend today and he said make the axle a coil spring set up. It would ride better and turn sharper so I looks like I will go that route. He has done 3 trucks that way. I might be able to weld the coil buckets or pads whatever they call them to the axle on the spring perch...watcha think on that?
In all reality the coil sprung axle swap is cake. There is a vendor that sells 8x6.5 unit hubs also. Just grab the trans of your choice and the tcase, BAM. 4wd and a dana 60 with 35 spline shafts.
I would sooner go with the stock 05-up coil/radius arm set-up than anything else. Since you are converting it, you aren't restrained by what you already have.
Travis..
Since you asked for opinions here's one that's not popular, not only would I not do it, I'd actually consider going the other way, 4wd to 2wd. I had to search to find me a 2wd IDI, damn near every IDI in California/Oregon is 4WD.
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