4wd Conversion on 1997 2wd Dually 7.3L PSD

[036speed]

SPECS
1997 F-350
I am the 2nd owner. Purchased August 2012 with 138k
7.3L Powerstroke Diesel
ZF5 Manual Trans
2 wheel drive
10.25 DRW with 4.10s
142,000 miles @ 6-11-13
Bone stock except for the exhaust
16" Alcoas with 235/85 Tires (were steelies with 215s)

PLANS:
Dana60 4wd Conversion using 6.0L coils and wedge radius arms
Divorced 205 case
DOM steering
3.55 Gearing
305/70R16 tires on OEM Alcoas. 2" spacers at the rear

Hyrdoboost brake system
Custom tuned TS chip for towing and milage. No race tunes.

________________________________________________________________

We had our first child on July 4th 2012. He has changed my life and its been very awesome! Just before he was born, I decided to sell my ECLB 2003 F250 with the 7.3L diesel mated to a ZF6 for a truck with a bigger cab.

I am a sucker for the 92-97 full size body style. I just love those things. So I began to hunt for a clean, 1-owner, white, 96-97 crew cab long bed, single wheel, 4x4, XLT, 5-speed F-350 with under 250k miles. I looked for several months. I learned that my definition of clean was different than many other people.

Then i found this. A black, one owner, 138k mile, crew cab dually powerstroke with the 5 speed. The only issue is that it wasnt a 4x4 and was a dually. While I am a fan of duallys, i dont need one. But i bought this one as I couldnt pass it up. I cant change the miles or the fact that I was buying it off the orignal owner.
So I drove 400 miles to pick this up in August 2012. I got a great deal on it.
I tried to live with it only being 2wd, but it just doesnt work with my life style. After getting stuck several times, I decided to do a 4wd swap over this winter. I will be keeping this truck out of the salt.

Ford did not offer a 4x4 crew cab dually in this body style. You could only get 4x4 duallys in regular cab chassis cab configurations. From what i hear, they did sell some CC DRWs in canada which made there way into Montana and such.

During the trip home after we got out of Chicago. I went from a truck with 35s and 3.73 gears to a truck with 30s and 4.10s. She screams down the highway haha.

After the first wash

Posing at the farm

Towing

Next to the Ranger

About 2 months later, the stock exhaust was replaced. I replaced it from the turbo back. I gained 1.5 mpg. I also added an intake, no pics though.

I am trying to keep this truck classy. So I added the classic turndown.

 

[036speed]

Then my buddy found this truck. He bought it to use it. Decided not to use it. So it was delivered to me for $1000. Its a 1987 F350, 351w, C6 auto. It has been sitting since 2002 and the intake is missing. So it doesnt run. But it rolls. That is what matters. This truck also has 3.55 gears which is a plus. I want to run 305/70/16 tires. About 33s.

Here she is. What a beauty. haha

I was originaly going to do a coil spring / radius arm setup. However, with the new born, I dont have that kind of free time for a project like that. So now I am going to stick with a leaf spring setup. I am also going to use a divocred 205 instead of the married BW1356 setup.

I am keeping the Dana 60, Steering, Steering Box (for my Ranger), front leaf bracketry, rear 3.55 gears, rear blocks and maybe the rear leafs.

I am trading the oem track bar assembly and front leafs for dually hub assemblies. Just need to get this truck apart. I will need to find front leafs for a diesel.

Everything else will be sold or scrapped.

Also, I will need to box the front frame horns on my truck. The 2wd trucks did not have boxed frame horns. However, I have discoverd that only the 92-97 trucks were boxed. The 87-91 4x4 models do not have a boxed horns. So I will have to see what I am going to do here. When i pull my front bumper off, I will see what I am working with. for now, I just want to get this truck torn down and start selling parts.

 

[PlumCrazy]

I was about to ask about the steering box, then I read you are keeping it for your Ranger....damn

-PlumCrazy

 

[Josh40601]

scribin. What a super clean truck. You could always convert it to a SRW. You already have the axles to do so...

 

[036speed]

scribin. What a super clean truck. You could always convert it to a SRW. You already have the axles to do so...

Thanks man. I thought about it. But finding a nice bed out here is impossible

I was about to ask about the steering box, then I read you are keeping it for your Ranger....damn

-PlumCrazy

I got the idea from you

 

[036speed]

I have been tearing into the truck after my family goes to bed.

After 3 nights, I have removed the doors, front clip, bed and cab. This weekend will be the t-case and trans. I sold the frame to a friend which is why I am stripping it down.

Got some better tires on the front

Pulled the plastic bed liner. Whoa

This is when I noticed the frames on this body style are not boxed. This might save me some work.

This is what the frame horns look like on a 92-97 4x4. I took then when my buddy was restoring his 1992 F350

 

[PlumCrazy]

My buddys 93 ext cab Cummins was not boxed either.

-PlumCrazy

 

[PlumCrazy]

Just use that bed on your Power Stroke for a srw. Throw some plywood down and call it good.lol. jk

-PlumCrazy

 

[036speed]

Just use that bed on your Power Stroke for a srw. Throw some plywood down and call it good.lol. jk

-PlumCrazy

HAHA. Get some black spray paint and done

 

[PlumCrazy]

As far as frame horns go, can you just knock the rivets out and use the brackets of the donor truck?

-PlumCrazy

 

[036speed]

As far as frame horns go, can you just knock the rivets out and use the brackets of the donor truck?

-PlumCrazy

As of right now, that is my plan. The rear brackets will be new from Ford.

 

[1badexplorer]

Those front brackets taht you are talking about are different for the 92+ trucks. I'm sure you could make the older ones work with some trimming. The newer style is made different for the bends in the front by your frame horns. As far as the other stuff goes its all bolt in for the most part. If you drill a few holes you can use all the factory stuff. You do need to run the track bar unless you plan to swap the shackles to the rear of the axle. You get a bad death wobble with out it and the factory shackles. You will also need to use the factory dana 60 pitman arm. the boxes are the same but the dana 60 uses its own pitman arm. I'm seen alot of trucks converted this way with factory parts. When you bolt that inside plate on the fram horns you will have to add a shim to the front shackles against the outside of the frame. The factory 4x4 frames have an indent there where the shackle bolt passes through. Otherwise 2wd and 4x4 frames are the same.

 

[036speed]

Thanks for the info!
Yeah, i looked at my buddies 92 last night. The front hanger is much different than it is on this 87. Like you said, on the 92+ the frame walls are indented on both sides and the shackle goes through. I have no idea what my 97 2wd frame horns look like yet.
I am also tossing around the idea of running the shackles at the rear and 'fixing' the front. I dont know what will work since I have not looked at my truck yet.

 

[dangerranger83]

So going to be watching this.

 

[036speed]

Got the cab out of the garage. Lifted it with ratchet straps hanging from the rafters. Then dropped it on the ranger to store outside until I make a scrap run.

Got the dually out for a bit to let her cycle the fluids.

Then I got stuck haha. Another reason to do this swap even though I do not drive it in the snow.

Got the 351W, C6 and front axle out. I ran out of cut off wheels so I will have to pull the rear axle and front springs at a later date. I am trading the track bar and front leaf springs for dually outer hubs. I still want to run a radius arm setup. We will have to see how much I get or owe uncle sam.