How to swap out a D50 for a D60

[Steve g.]

Hey guys,

Anybody ever swap out a D50 for a D60 in your 250? Well by the time were done with this thread hopefully you'll have learned each detailed step to swaping out your IFS for a solid front axle!
I hope I learn to because I don't have a clue how to do it either

Please all those with knowledge and maybe those of you who are bored at work (ahemm.. cough, mud, cough) share with the rest of us how to swap out axles... doesn't matter what axles either btw (better learn something than nothing). Just basic/detailed intructions and *pictures* .

Thanks to all of you in advance,

Steve

[junior3382]

Okay, this is a great idea for a thread, especially since there are an enormous amount of people out there looking to do a swap.

Now I have never personally done it, but I am taking on this adventure this comming spring. Things have finally lined up favorible for me to get it done..... but that is a story for another time....

[junior3382]

So allow me to get the ball rolling on some suggestions....


Most of the time, a solid axle swap, or SAS is needed when more serious wheelin is done for strength, and for when the lift required to run the tires you want on and IFS system is greater then 6-8"...

Most mid sized trucks all have IFS systems, with the exception of JEEP... and some full size comapnaies also run IFS, GM being big on it. All are capable of being lifted with theory of dropping the IFS down up to 5 inches.... other routes are body lifts, and those can accomidate for up to 3" of lift.

Anything more then this generally requires a solid axle. For the mid sizers, the Dana 44 is usually the first choice. Most get them out of jeeps while some buy brand new.... For the full sizers, the Dana 60 is the axle of choice.

Now.... this is a big job. Not only do the IFS components have to come out, a whole new suspension system will have to be designed and installed... There are three major types from what I understand.... 75K30 may have more to add later...

Leaf spring- usually the way most people go. Inexpensive, and easy to get parts. great flex, but ruff ride. Generally used more for strictly off road use, can create and uncomfortable road ride.

Coil Spring- This will be more usable ON road... most times the shocks remain outside the coils. Great flex, long travel possibilites and a much more comfortable on road feel. More expensive, but parts are still easy to find.... Losts more welding and fabbing needed in most cases..

CoilOvers- now I may have the name wrong, but this is when the shock runs inside the coil. Close to like struts on your daily driver cars. This can be the most expensive conversion due to parts being the hardest to find. Lots more fabbing to do, but end result is much cleaner, more usable suspension system. Great flex and the best on-road ride quality....

Things to keep in mind:
*Most exhaust will have to be cut and rerun
*Most front and rear drive shafts with more then 5" of SUS lift will require lengthened
*Most trucks need a new cross member for the tranny support and sub frame to allow for the front drive shaft movements
*Brake lines need lengthened...( brake upgrades are recomended to stop the higher weight loads )
* this is not a single day, do it yourself job.... It takes time, welding skills, and lots of patience...



I do not want to hog this thread, but I was waiting for something like this to pop up. I have as of yet have not done this like I said, but will this spring. I am sure I left some things out, and will continue to add, but sometimes it is nice to have a whole post with plenty of info.

[junior3382]

Here are some pics to illustrate.... Sorry I am very passionate about this subject....


Leafs...




Seperate coils and shocks



Shocks inside coils...

[junior3382]

Sorry they are all S10's.... kind of my favorite truck, so pics were handy... either way concepts still the same....


Okay i am done for now... feel free to critique to add to what i have already... hope this was really where this thread was going

[Steve g.]

This spring? It's summer now.... spring is gone... do you mean next spring???

[junior3382]

yeah sorry, NEXT spring....lol...

[mudseeker]

i've swaped an axle for an axle on a few late 70's chevys, but never done an IFS to solid swap yet.

[junior3382]

Just a one more thing to add to my previous posts...

Other things needing to be considered... every IFS system runs a rack system of some sort for steering, utilizing tierods... where as a solid axle, though simpler, runs direct from the steering box to the linkage. This is something I know 75K30 can explain soooo much better.... but I wanted to add that.

[junior3382]

Here is a time laspsed video of a solid axle conversion on a Toyota IFS front end... he used the leaf spring pakage... check it out


WATRD Solid Axle Swap Time Lapse