Picture Heavy Super Duty Axle Swap

CanadianStroker

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Sorry about the links, says the pictures are too big. They were just taken on my phone. Not sure on how to re-adjust them, as I'd like to have them show on the thread.


Hi all,
Never done a build thread before, but always wanted to start one. It seems like not too many do them anymore, so I thought from my years of reading I should contribute now. Didn't get any information on my questions in the last thread, but maybe with pictures someone might be able to answer a couple along the way for me. The axles I will be( and in the middle of swapping in) using are 2004 Super duty axles off my old Harley Davidson F-350. My truck is a 1997 F-250 5-speed and 4x4. Super Cab short box.

Been working on the truck off and on for a few weeks, but gotta get her done before winter.

List:
PMF 3.5 RSK
PMF 3 inch drop bracket
PMF Track Bar
3 inch drop pitman arm
Rear axle front hangers
Front axle rear hangers
New Rad support
New front fender liners
OEM Ford tow mirrors
Clearance lights
Parts for fuel system
(will add as I remember)

Here is my old Harley truck I used as the donor..
https://imgur.com/xnhbozF
https://imgur.com/yDa5oTu
Slowly started to part it out and keep some parts..
https://imgur.com/raajBld
Sold the cab off with for the interior, sold the engine to my grandpa for his '06 and I'll be putting the suspension, axles and wheels/tires on the 1997.
https://imgur.com/RLWMpN6
Then my new truck came along..
https://imgur.com/82YqgQL
I seem to have trouble to be uploading the other pictures of where my current build is...But will upload later tonight when I figure it out.
 
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sootie

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Before those posts time out for editing, open them and hit the "go advanced" button. Then look for the "manage attachments" button below. There is a size limit for each photo but it should work.

Either that or host your pics on imgur or something like that and paste the link here.

Where in Ontario are you?
 

CanadianStroker

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I think I screwed up, post not letting me edit them to add pictures...Great.
Anyways moving on I guess. Now that I've been looking through the pictures, it seems I didn't take as many as I originally thought.

Started with the easier part first, as I already had the truck in the proper position to pull the rear axle out first. Pretty straight forward. I'm working completely outside and don't have all the proper tools, but it seems to work for me so far.

The skid steer has to been one of the most universal equipment I've used. Been very helpful for this build the entire time. Even though I may have found its max lifting weight..

The pictures that I have,

https://imgur.com/J3ZnS1Z

https://imgur.com/F2LMFdT

https://imgur.com/5rxRMJ6

Replaces the rear axle hangers infront of the axles as this one has a couple windows in it. I stuck a piece of bondo through the one hole.. and the other one is in the middle of it, kind of hard to see.
https://imgur.com/1MDZh1o

I want the truck to last up here as long as I can make it, so I cleaned the frame with a wire wheel and then used the POR 15 metal cleaner, then used the POR 15 Semi Gloss I think black paint. Did a couple coats, But I'm not the best painter.
https://imgur.com/xb4PhIp

https://imgur.com/H4L9OKv

Got the rear Super Duty axle in, waiting on hardware for it.
https://imgur.com/1kGy5wy

https://imgur.com/Fhg9rij

https://imgur.com/vYtkRPX

https://imgur.com/1lONYkR

I also cleaned some more of the frame and painted it.
https://imgur.com/ZRKfI5X

https://imgur.com/shcls3d

When I find more pictures I will add them
 
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CanadianStroker

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The next day I got the truck turned around, also using the skid steer. Still have work on the rear to do.
Change yoke on rear axle, Question: I have my super duty driveshafts still, but my super duty shaft is too short to bolt up. But theres guys using the SD drive shafts? Could someone help me out with this?
Install driveshaft
Install new flex line from frame to axle(not sure of length at the moment)
Install new pads and rotors
Most likely need a lift block, but unsure at the moment
E-brake cables and shoes(but might just do that in the spring)
Change differential fluid
I think thats it...

Onto the pictures, Front of truck now starting disassembly.
https://imgur.com/WXnefxt

https://imgur.com/9diRkOK

https://imgur.com/02NEZIK

Look at all this good northern rot, and previous owner claimed rust free...
https://imgur.com/2ZrVkNp

https://imgur.com/pwBD9WG

https://imgur.com/dKsF3yl

https://imgur.com/U4sBKpd

Truck does have the Banks Technicooler system, And the holes that the shop cut into the rad support were probably not some of his best work...
https://imgur.com/aL6kmmG

https://imgur.com/N4GyOlx

https://imgur.com/p4dqpTf

Would these be production numbers?
https://imgur.com/my4y74u

https://imgur.com/9diRkOK

https://imgur.com/02NEZIK
 

CanadianStroker

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Just got the news that our family dog is only got 2-3 months left:(
https://imgur.com/G3pJ7np
https://imgur.com/eqqj699

I ran into some issues with getting the front axle out. The bolts that go into the rear of the front leafs were not coming out for the life of me. Torching them and everything trying to not hurt the bracket. Wasted a day on it, so I had decided to just cut the bracket off...Bad idea. I didn't realize that they weren't made anymore. I was freaking out. So I looked through forums as I couldn't be the only person with this issue. I found that Sky Offroad made a pair and they would have been perfect, but it was Friday(or Thursday) afternoon I believe? and they were closed...I need to order ASAP. So I found ATS springs said that they made them over on an older FTE thread. Looked on their website, they don't list them. So I called, just to be sure. I believe it was Bob that I talked to and he was an awesome guy to deal with. I'm very happy with the service. I got exactly what I needed and no pressure.

https://imgur.com/sjfJzfy

https://imgur.com/kpZXnVf

Then removed the TTB with skid steer
https://imgur.com/HtnfVk9

https://imgur.com/tPg1b5f

https://imgur.com/4Jf0uKE

The front fender to rad support brackets were another thing that I found no one makes, so I found a guy about an hour away that parts these trucks out, so I got a few parts including a mint pair of brackets from him. Debating whether or not to paint them in POR 15 as they still have the factory red under the under coat..

https://imgur.com/fP2gv1o

Also scored some mint factory Ford tow mirrors...
https://imgur.com/i7eTd4k

Had to get some front inner liners too, as mine did not want to come out nicely, and the torch kinda melted them too much...
https://imgur.com/lgABCVy

Next I got the rad support out or whats left of it...
https://imgur.com/wfkM2c0

https://imgur.com/Xd90xCV

I cut the rest of the front axle rear brackets out and cleaned up the frame and painted it. Also cut the old rad support mounts off and painted that area too.
https://imgur.com/jOsB5RA

Now I know I'm missing pictures as I have some of the new Rad support brackets somewhere. Was real excited to get the PMF RSK bracket on there, had to use a HiLIft jack to spread the frame just enough to get the PMF bracket installed.
https://imgur.com/DsY6kGA

https://imgur.com/skm9BKB

Heres a picture with the rad mount supports on. Kind of hard to see in picture, but they are installed.
https://imgur.com/aFRfLDD

Here is one of the brackets installed I got from ATS, my painting skill suck and even when I painted the bracket in thin coats, it still dripped..gotta work on that. POR 15 also on the bracket.
https://imgur.com/nJgEXqX

This is where I'm at right now, I have to drill holes in the brackets to get the 3/4 sized bolt in the brackets. Tomorrow I will update hopefully.
 

CanadianStroker

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As you could tell by some of the pictures my paint skills need work. I've never really painted before on something this important. But I need new fenders for the truck along with cab corners, etc. I've got the metal for most of everything that needs to be fixed but I'm getting some help with the welding process.

My front fenders. Thought the Harley badge might be cool to add.Instead of using the classic F-250 badges.
https://imgur.com/hG2MWXO

Starting the paint process, just using rattle can spray bombs from CarQuest. It's much cheaper than the $1100 quote I was giving to have a shop paint them. This was only one can of spray paint, I'm thinking 2 will do it nicely? Then I will have to add the stripe, I hope I don't screw that up.
https://imgur.com/WCM1oUA

Still the one can of spray bomb on it, but wanted to see what the Harley badge looked like on it.
https://imgur.com/LEsVggF

I did also paint the PMF track bar and 3 inch drop down bracket the factory red color. Just to change the under side up a bit. they came out pretty nice I must say.
https://imgur.com/GxzgKdp

Then I got bored with the POR 15 as I was waiting on parts the one day. I painted the rear leaf spring packs. I think they look alright, will paint the axle when I can get the truck back in a hoist.
https://imgur.com/uF7aFiJ

https://imgur.com/FFjwxsC

That's all I got on painting right now as well. Hopefully this is picture heavy, and sorry for making you guys do so much work with the links, wish it would just post on the page.
 

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