97 F250HD solid axle swap questions

[77f2504by4]

Hi all,
I have a 97 F250HD 351w 5spd, and the front axle is the ttb Dana 50. It needs some work, (read ball joints, and new leaf springs) and I don't like the ttb setup anyway so I want to do a solid axle swap.

I have a whole truck for a donor, with the same axle ratio. The donor is a 94 F350 7.3 idi diesel automatic.

I have been reading up on this swap as much as I can, but I still have a few questions.

1. Will the drive shaft from either truck work or do I need to get one from a 5 speed 351w f350?

2. I read that the 95-97s have bigger front brakes, is that true? If yes, can I just buy brake parts (rotors, calipers, pads, lines) for a 97 and bolt them on? Or should I stick with the smaller 94 brakes? Will there be any noticeable difference in braking if I use the 94 parts?

3. When the swap is complete, will the ttb stuff bolt up to the f350 so that I can sell it as a rolling parts truck? Or should I scrap the left overs?

Thanks for any help. I need to get this done soon because my inspection sticker is due soon.

 

[primetime]

1. Kinda sorta, maybe. Dana 60 is longer and requires the driveshaft to be shortened. I used my original driveshaft and so far haven`t broken my t-case. Which leads to the other part. I bought the F-350 shaft when I bought my axle. This is important because the F-350 shaft has a double cardan joint on the t-case end so they don`t vibrate because of the extra height of the F-350 springs.

However, the shaft would`nt fit (E4OD v C-6). At 45 mph I have enough vibration to rattle the t-case lever. It`s worse in 4x. This leads to the next problem. You need a different yoke to run the 350 double cardan shaft. According to the shop I called about shortning the 350 shaft, Borg-Warner
used two styles of splines during these years, voluted, and convoluted. Whichever was handy at that particular time I guess. Which means they need my yoke in hand to get the right one. So that waits till summer.

The guy I talked to has a 95 F-150 lifted 6" with a double cardan shaft.

2.My axle came out of a 97 cab and chassis dually. Yes, the rotors where slightly bigger. I cannot speak for srw trucks. I used my 93 TTB rotors, the 97 calipers, and pads, and my 93 lines. My rotors were better, but here soon I will buy new 97 drw rotors and EBC Greenstuff pads and be happier about life.

3.I imagine you probably can. I wouldn`t waste the time though. You are keeping the one part that really makes an F-350 chassis valueable.