front axle swap

02POWERSTROKE7.3 · Jan 31, 2012

Has anyone swaped a 05+ front axle in a 99-04? I got a 02 F250 2wd I would like to make a 4x4. Would like to go to the newer front suspension if it would not be an issue.

cfdeng7 · Jan 31, 2012

It requires a fair bit of fab skills but it can be done. The lug nut thread pitch changed in I think 03 but someone might correct me. Frank the tank put an 05+ axle in his obs and did a really nice write up. Ill see if I can find it

02POWERSTROKE7.3 · Jan 31, 2012

I know the lug nuts changed and i believe the axle is wider than the 99-04.

Aaron S · Feb 1, 2012

The lug pattern is the same, newer axles use fine thread versus coarse on the old trucks.

Ive done the swap on my 4x4 02 truck. There isnt any real fabrication, just a lot of drilling. I believe the axle is 3 inches wider on coil truck versus leaf sprung truck.

The coil buckets line up perfectly. The radius arm bracket didnt line up perfectly with all holes on my truck. Line up the track bar bracket with existing holes and drill out the others. Bend hard brake lines to match locations of 06 soft lines. Reuse stock 2wd anti sway bar. Can install 06 steering box, by drilling frame mount holes, get bolts and pressure line or install 4x4 pitman arm and increase the size of the tapered end.

My only real nagging problem is some bump steer that is going to require a custom track bar bracket, that I am working on.

If you have any questions just ask.