1997 f250 straight axle swap - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 16 (permalink) Old 11-05-2018, 08:24 PM Thread Starter
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1997 f250 straight axle swap

I just purchased a rough country 4in lift. I have all new steering parts and steering gear box. My main question is, How do I connect the drive from my f250 to the f350 axle?

I was told that I could mate two U-joints into one working part and use my f250 drive shaft, is that possible?

Thanks for the help

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post #2 of 16 (permalink) Old 11-05-2018, 08:50 PM
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Re: 1997 f250 straight axle swap

first off, it depends on what year axle you are going to use.
personally i would use everything from the F-350.
axle, spring, steering linkage, and driveshaft so when going for parts in the future you just need to tell the counter monkey: i need @#$% for a F350 4X4 whatever year the parts came out of.

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Last edited by tjctransport; 11-06-2018 at 10:30 AM.
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post #3 of 16 (permalink) Old 11-05-2018, 11:56 PM
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Re: 1997 f250 straight axle swap

You really need the dual cardan drive shaft from the F350

96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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post #4 of 16 (permalink) Old 11-06-2018, 12:36 AM Thread Starter
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Re: 1997 f250 straight axle swap

Damn, I guess ill have to find a decent used drive shaft. The axle I'm using in from a 1996 f350

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post #5 of 16 (permalink) Old 11-06-2018, 04:52 PM
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I did the swap a few years ago and used the same front driveshaft. But with a lift you would have to lengthen it.
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post #6 of 16 (permalink) Old 11-06-2018, 05:49 PM Thread Starter
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Re: 1997 f250 straight axle swap

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Originally Posted by 97obs_stroker View Post
I did the swap a few years ago and used the same front driveshaft. But with a lift you would have to lengthen it.
Did you have any issues with its function? how would I lengthen a drive shaft?

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post #7 of 16 (permalink) Old 11-06-2018, 06:58 PM
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Machine shop would lengthen it. Just need numbers to give them. Havent had any issues with mine. Everything bolted right up. I use it often, i gut firewood in my days of so it gets abused a bit. Hence why i did the swap. I broke two ttb front diffs chained up. Havent had any issue with the d60
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post #8 of 16 (permalink) Old 11-06-2018, 07:03 PM
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Re: 1997 f250 straight axle swap

One thing on the F250's is that there was a TSB out that covered replacement front drive shafts if there was a vibration from the front end as you drove with the front hubs locked in. That is how I got the F350 double cardan drive shaft on my 96 F250.

On lengthening it you might want to see if there is a drive line shop in the area that you live. There is more to it than just adding a length of metal to make it work properly. A lot of machine shops are not set up to do it correctly.

96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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post #9 of 16 (permalink) Old 11-06-2018, 09:05 PM
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They would have to balance it obviously
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post #10 of 16 (permalink) Old 11-08-2018, 03:08 AM
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Re: 1997 f250 straight axle swap

Balancing has nothing to do with the vibration issue. It's a matter of angles at either end of the driveshafts not being equal and offsetting. The dual cardan shaft corrects this issue.

Running a dual cardan driveshaft requires changing out the yoke at the front output of the transfer case.

On the subject of balancing it can be avoided if runout is removed from the shaft. However, it's easier/faster/cheaper for a production shop to balance as an alternative.

In my area there are specialty driveshaft/driveline shops. It takes a big lathe to build driveshafts in.


The actual swap of a Dana 60, including the parts required, is well documented on this site and others.
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