Solid axle swap, 80-96 1/2 ton and Bronco

[surewhynot]

Here is how I did the solid axle swap on my 94 F150, using a straight axle and radius arm setup from 78-79. The TTB front end is the same from 80-96 on F-150's and Bronco's so if you have on of those, it will be the same. There are many different ways to do this swap, here's what worked best for me. I went for 12 inches of lift to clear 40" tires but you can do it with as little as 4 inches of lift if you don't mind trimming the crossmember so the pumpkin doesn't hit it.

Tools required-
Sturdy jack stands
Jack
basic hand tools- sockets, wrenches, measuring tape, etc...
tie rod fork
pitman arm puller
grinder
drill
welder

Some basic fabrication skills are needed, but It's not difficult.

Start by removing the TTB front axle and radius arms. Also you will have to remove the old radius arm brackets, the coil springs and shocks. Here's a picture of it with everything removed. Sad looking.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas2.jpg

The next step is locating the new front axle. I measured off of the rear axle to get it centered where it needs to be. Take careful measurements. Don't be afraid to have somebody double check you.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas1.jpg

You can use your stock coil buckets in the stock position, or raise them for added lift. I bought aftermarket replacement buckets from www.broncograveyard.com. I used 6 inch lift coils along with lowering the buckets to acheive my 12 inches.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas8.jpg

You will have to locate and mount the radius arm brackets for the 78-79 and bolt or weld them on to the frame. I did both just for safety. You will also notice that I used a dropped bracket because of the amount of lift I was after.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas4.jpg

I also had to use 7 degree radius arm bushings to get my front end geometry right for the 12 inch lift. Now is a good time to use all new bushings.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas10.jpg

Hooking up the steering isn't complicated. Use the tie rod for the 78-79 axle.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas6.jpg

To hook that tie rod to your stock steering box, use a drag link from an early 90's F350 4X4. It has the correct size ends to put it all together.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas12.jpg

Now that the steering is hooked up, it's time for the trac bar to keep the front axle in the correct position under the truck. To keep from having bumpsteer, it is necessary that the trac bar is parallel to the steering drag link. I used the stock 78-79 trac bar and fabricated a new mount for it in the correct position.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/tracbar.jpg

Here are a couple of shots of the finished ride height.
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sas13.jpg
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sasfinished.jpg
http://i111.photobucket.com/albums/n146/i_call_me_Tony/94 progress pics/sasfinished2.jpg


When doing any fabrication, always know your limits. If you aren't comfortable with your level of skill, please ask for help. It is the lives of you and many others to worry about. Always overbuild when it comes to safety. This is just some basic info. If you have any questions, feel free to ask.

 

[slmann]

very interesting post, thanks for sharing.

 

[Blue Goose]

Tony, you do good work........what a neat project!!

 

[Brian_B]

Good deal. We need a lot of these sort of write ups. Thanks for sharing.

 

[surewhynot]

Thanks for the compliments guys. Sorry I didn't get back to ya sooner.

 

[Blue Goose]

I'm gonna bump this excellent post of Tony's back to the top for those that haven't read it...

 

[surewhynot]

Thanks Brad. The straight axle is the best mod I've done to that truck.

 

[msb71]

Looks great Tony , you say it can be done with only 4 inches of lift, pretty much the height of a stock F-350 4x4?

Mike

 

[surewhynot]

Yup, but with only 4 inches, you might have to notch the crossmember for the front pumpkin a little.

 

[Mr. Stroker]

Wow, im dreamin for the day i can do that to my bronk. Looks awesome man you do Excellent work! Amazing.

 

[lenny1carl]

git your ass up here and do that to my truck.....i'll let you touch Sassys butt. she'll hate it but she's bait for perks. she loves daddy.(me..not you)
good job...and the pics are cool.

 

[surewhynot]

To close to hitler up there Carl. Bring your truck down here.

 

[flareside_thunder]

Glad I found this tech article man I'll be usin this and callin you for info when I do this to my 80......reps

JR

 

[surewhynot]

Thanks man. Glad I can help.

 

[Lost]

Thanks man. Glad I can help.

Hey I was reading up to do this on a farm truck . They said that the 79 solid rad arm bracket had a hole that would line up with a hole around/on tranny crossmember area . And would help line thing up. Just wondered if was true?

 

[lil_dq]

Great write up Tony!

 

[surewhynot]

Hey I was reading up to do this on a farm truck . They said that the 79 solid rad arm bracket had a hole that would line up with a hole around/on tranny crossmember area . And would help line thing up. Just wondered if was true?

The radius arms are longer for the 79 front end. That puts the brackets past where the crossmember would be on the later models. I had to drill all new holes. But, a few careful measurements and no problems.

 

[TexasNomad]

Your one bad ass piglet Tony you should get some video or audio of your stroker i'm sure it sounds bad ass.

 

[godblessmud]

he just posted a vid awhile ago of him roasting the 39 michys

 

[TexasNomad]

Hmm I can't seem to find that..