Hello. I've never posted here, but often read here, so I figured I'd share. I have a 2004 F250 CC LB 4x4 6.0L with a 4" lift. I'm swaping the axle and suspension from a 06 F250. So far it has not been to bad. Here are some pics:
donor:
Some work being made:
goodies:
I've have to drill 10 holes and resize about 10 more, otherwise its bolted up fairly easy. The biggest problem I'm having is finding the high pressure power steering hose that goes from the hydraboost to the gear box. The port on the 06 gear box is bigger than the 04. The problem is the part (Ford part #5C3Z3A719C) is on national back order and I have not been able to find one yet. Also, no one yet makes an aftermarket oem one. So if you see one let me know please. Well, let me know what you guys think. Thanks.
Looks like a pretty good install, Im planning to do the same to my Bronco as soon as I can track down some axles that they dont want two million dollars for
as for your hose problem,what about having a hose made for it locally? If you can figure out what fittings you need and a length they should be able to make you a hose in about 10 minutes. I used to do emergency road service on trucks, and whenever I needed a high pressure steering hose I would have it made at one of the hose shops around here. It was far easier than tracking one down from a dealer
I have been to just about all the major shops around my area and they all say if I bring them the fitting, they can make a hose. My problem is I don't have a fitting. A few have tried to make something work, but none have come up with a solution yet.
I just completed the same conversion, have you found out yet that the 05-07 pitman arm will not work either, this is why I just switched my whole steering gearbox to an 05. Maybe you have arleady adressed this issue, the hole in the drag link end is a bigger on the 05-07, as well as the splines in the gearbox end. Just a heads up. If you haven't encountered this yet and have any questions ..let me know. Ther are a couple other issues you will encounter.
That looks very nice. I almost got the bds 4-link, but got the Icon 4.5" form trucktoys. I'm using the gear box off the 06. That is why I need the 06 high pressure line. I've been told that you can use the 04 gear box with the stock pitman arm, but you have to find a shop to machine it to the 05+ specs. I'll hit you up for sure if I have any more questions. Thanks.
I just completed the same conversion, have you found out yet that the 05-07 pitman arm will not work either, this is why I just switched my whole steering gearbox to an 05. Maybe you have arleady adressed this issue, the hole in the drag link end is a bigger on the 05-07, as well as the splines in the gearbox end. Just a heads up. If you haven't encountered this yet and have any questions ..let me know. Ther are a couple other issues you will encounter.
Here are some picts of my conversion. I used a BDS 4-link setup.
What bolts did you use to bolt the 06 gear box on with, On my 2000 frame the factory 05 bolts only went in about 3 or 4 threads, the frame is a tad thicker on the older trucks. I used 6-Liter head bolts.......cut down a few inches, Had plenty of thread then.
I got some some bolts just like the factory bolts (which are 14mm x 2.00 pitch @ 120mm) but are 140mm long. You are right the 05+ newer frames are recessed and the bolts are too short.
Did you get a new high pressure hose from Ford? I have been looking everywhere I can think of and still have not found one.
Does anyone have a spec sheet for the power steering box or know what size the port is on the power steering gear box? I'm wondering if I can find an adapter to make this work.
Did you use the high pressure hose from a 05+ or did you find an adapter? Does anyone have the specs on the gear box for a 06 or maybe someone can tell me what size the high pressure port is? I hope I can find an adapter so I can use my 04 hose, as i can't find a 06 hose to save my life. Thanks.
Great Job FSD,
A couple questions if you don't mind.
Is there a common term or standard for the tapered mounting hole in the pitman arm? I.e can I take it to my favorite machine shop and tell them to give me a #7 taper with a cherry on top, and they know exactly what I want?
Maybe someone on this board is a machinist and will set up a program for re-reaming pitman arms for this mod???? Anyone???
Just a thought.
On another note, is your '06 axle a Dana 60?
Is there any other differences in the '99-'04 axles, other than the coil mounts that is? You know like the oh-so-wonderful unit bearings?
Bill, I would guess you would have to take them a 05 pitman arm and let them figure it out. I do not know what to tell them to have it done without the newer design in hand. You could also try it like Cary said and swap the drag link.
From what I know (which agian is not alot here) the 05+ newer axles have bigger brakes, differenet knucles, coil suspension, all of which is susposed to help it turn better, and yes, is stll a Dana 60. Ford still kept the non-serviceable bearings, but they are different than the 04 because of the different knucles.
Well, I found a hose finely and my cousin and uncle finished my truck (I had ankle sugery) for me. I drove it today taking it to get the alignment done. The ABS light came on the brakes are funny. When you hit the brakes, the truck dives to the left then balances out. When you let off, the truck pulls to the right for just a second. The alignment guy thinks the abs is affecting it. He said that it has a proportional valve. He's a good mechanic and I have no doubt he will get if fixed. And yes the ride is so much better and turning is amazing!
It sounds like you have a restriction in the hose going to your right front brake. That would cause exactually what you are describing. Either you have a dented steel line or a flexable line that is damaged in some way.
I was thinking that the caliper might be sticking bad or not sliding good. I didn't thank about that, I'll call and tell him. Unfortunely I can't do any work on it, aleast he's a good mechanic and he'll figure it out.
Well, I've only driven it once, but the ride was night and day. I don't know what shocks it had, whatever the dealership put on it when they did the lift...aka p-o-s shocks.
All but the top holes (on the side of the frame) are there and one bottom holes has to be drilled too. I think it take three on the bottom, five on the side.
Your problem under braking sounds like a steering geometry problem, the angles and/or lengths of the track bar and brag link do not match well enough. To check it, remove the front shocks and get a couple of guys to bounce the front of the truck while you look at the front wheels to see if they steer slightly.
Well, the truck is aligned and acording to the shop, the suspension looks good. I believe he did do some measuring, comparing, and checking with a 06F250 with a 4" lift he had there. The truck drives stright, just when you use the brakes, it goes crazy. I think there is a problem with the brake fluid flow (pinched or bent line). When I was bleeding the brakes, the drivers side had good flow and lots of pressure. The passenger side didn't even have half the flow or pressure of the drivers side. Now, it wouldn't matter what side I put the Skyjacker brake lines on would it? They looked the same and were the same length. There were no instructions, so I just put them on. One line would not be a different size inside, thus having a different rate of flow.
I converted my truck from 2wd to 4wd using this axle, I could not believe it but the truck rides just like the 2wd, it is a BDS 6 inch, 4 link kit, it is truely amazing how it rides.
The 05 up trucks ride a lot nicer than the leaf fronts could ever dream of. I have enough stuff here at the shop that I could do this, except I don,t have a 3.73 front axle. Got a 430 instead, LOL. I would run the new gear boxes to for the reason that their a lot stronger if your gonna go off roading at all. I,ve seen too many come though here withthe pitman shafts twisted off just from hitting curbs and other things. The draw back is if you do some thing like that it wont break the shaft, it breaks the box itself. Have a few of those here too.
Your problem under braking sounds like a steering geometry problem, the angles and/or lengths of the track bar and brag link do not match well enough. To check it, remove the front shocks and get a couple of guys to bounce the front of the truck while you look at the front wheels to see if they steer slightly.
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