Sal's K2500 Dana 60 Solid Axle Swap

[strikk]

Brakes. 2005 gm hydroboost and master cylinder 2x 1/2-20” 3/16” tube out into 2x 3/8-24” 3/16” tube with a Wilwood 4444/30 260-11179 proportioning valve.
I deleted the gm ABS unit.
The front calipers are fed by 2x 3/8-24” 3/16” and the rear is fed by 1x 1/2-20” to 7/16-20” adapter into a 7/16-24” 1/4” tube.
Front and rear brake hoses are Offroad Design stainless braided lines. I am running a matching generation AAM 11.5” rear end with disc brakes and a ‘97 Ford Dana 60 front end.

 

[strikk]

I made a downpipe from 3” stainless. It was the largest diameter tube I could fit between the starter and the front leaf spring bracket.

 

[strikk]

Cummins making Cummins sounds:

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[Orpedcrow]

Those are good sounds.

 

[strikk]

Steering time!
Oe steering gear hooked to an ORD Offroad Design 3.5” drop pitman arm, ORD custom offset drag link, to a milled passenger dan 60 knuckle with a steering arm. Super simple and worked pretty well

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[strikk]

When I did my measurements for my driveshafts I realized the rear pinion angle needed to be lowered by nearly 3 degree's, so it's time to pull it apart, cut off the perches and
adjust things....

AAM 11.5" rear ends are not a direct bold on for our frames, their factory leaf spring perches are too wide. I ballparked it when i tacked on some ruffstuff lead spring perches at the correct width, but wasnt as perfect.

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[Lou32]

I've been collecting parts, trucks, and tools for some time now and can finally my SAS is in progress.

I sourced a 3/4 ton frame in excellent shape and with my luck the kid didn't want to pull the 350, harness, ECU, 4l80e, or tcase. A few weeks later my friend's father pulled the motor out of his k1500 for his jeep project and was about to junk the rest of the truck. I stepped in and got it along with the title for free(!!)

My goal will be a registered '97 k1500 sitting on top of a '97 k2500 frame running 8 lug Dana 60 balljoint front end and 14 Bolt rear end. Time will tell if the motor is in good shape after I tear it down, if not then I will be open to swaps or what ever deal can comes my way.

Feedback is always welcome. I'm learning as I go and honestly I think the only thing I have going for me is my patience. I'm not very skilled in body work or being a mechanic but I'm not afraid to read!

The goods
Cab: '97 K1500 Extended Cab
Chassis: '97 K2500 Extended Cab Long Bed
Motor: sbc 350, Supposedly 140k miles and in running condition
Front Axle: Ford '97.5-98 Dana 60HD: BOM# 610741-5, 4.10 Gears
Rear Axle: SF 14 Bolt, 4.10 Gears
Front Brackets: Offroad Designs 36.5" Width SAS Kit for 47" Springs
Rear Brackets: Offroad Designs Shackle Flip
Steering: ???
Front Leafs: ??


Cab is currently in the yard, I have the full front clip as well for it in the barn already. I've been picking pieces off of it over the past few weeks labeling and organizing everything as I go

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The fame the day I picked it up. It is in excellent shape for being in New England it's entire life. It is missing a few crossmembers in the rear that the kid had snagged for his other projects. I was thinking of putting in the 42 Gal suburban tank since why the hell not?

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Frame making it's way home

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Axle making it's way back to the barn. According to the BOM numbers it is a '97.5-'98 Ford 'Dana 60HD'. It is a balljoint dana 60 that I choose to go with because during the 96+ model year they had better front caliper options. I need to get the passenger side knuckle shipped out to be machined for crossover steering. Any recommendations for steering?

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Perhaps a moderator will move this post to the hot chicks and fast cars thread