How easy or affordable is it to swap a '94 Ford HP 60 to 5 on 5.5. I emailed Dyna$#% (I can't even say the name), and for just $2000 more I can run 5 on 5.5. The only reason to do this is to keep the fully built 9 inch I have in the rear. If it's a pain or too expensive I will swap the 2nd HP 60 I'm getting into the rear and go rear steer, although I don't need it.

You won't be able to get GM calipers to fit on a smaller diameter rotor with the Ford knuckles. You would have to find some sort of low profile caliper if you try to do this.

Originally posted by coyote11
How easy or affordable is it to swap a '94 Ford HP 60 to 5 on 5.5. I emailed Dyna$#% (I can't even say the name), and for just $2000 more I can run 5 on 5.5. The only reason to do this is to keep the fully built 9 inch I have in the rear. If it's a pain or too expensive I will swap the 2nd HP 60 I'm getting into the rear and go rear steer, although I don't need it.

Do a search there was some talk about this using some D50 parts or just look here:

http://www.bc4x4.com/tech/2001/hpd60front/ :flipoff2:

While not cheap this cures the caliper fitment problem and is bomb proof taboot!
Knuckle (http://www.wagonermachine.com/knucklepage.htm)
They also do the 5 lug converstions for the hubs.

As an alternitive why not either have 8 Lug axles made for the 9" or convert it to full float with 8 lug hubs as long as your happy with your 9". Check with some of the folks that make wheel spacers and adapters you should be able to find a set of adapters that will convert from 5 to 8 lug I've seen several competion rigs with them.

Step outta the box.

Can you swap your rear axle shafts on your 9" for an 8 lug pattern?

It can and has been done.

The TJ we ran for ERoCC had it done to the front. I don't have specifics on the process but PM me and I'll get you intouch with the guy who can make the stuff for you, or tell you how to do it.

Well here is mine. I used just stock 73-79 Chevy half ton calipers. They fit just fine. Made a custom bracket to hold them. I know in the picture the caliper is up-side down. But, here are some pictures. I have more pictures of it...

http://us.f1.yahoofs.com/users/aa67ba02/bc/BigJeep/Disc+Bracket%235.jpg?bcCduu9AfVlsTPAY

http://us.f1.yahoofs.com/users/aa67ba02/bc/BigJeep/Disc+Bracket%233.jpg?bcwguu9AHGV5Xcub

http://us.f1.yahoofs.com/users/aa67ba02/bc/BigJeep/Disc+Bracket.jpg?bc.huu9AyHSYIjFD

To my understanding, 4Wheeler magazine converted a front 60 to 5 on 5.5 a while back. A buddy of mine actually got to talk to Rick Pewe about it at a show. This is what he said (and what my buddy is having his machinist neighbor do to his front 60):

The conversion used the original D60 hubs re-drilled with the 5 on 5.5 bolt pattern. According to Pewe, the biggest problem about doing the conversion was the hub itself.. it was simply too big to fit through a standard size center hole on a 5-5-5 rim. So what they did was put the hub in a lathe and mill it down until it would fit. Since most 60 hubs are tapered anyway, what this did was simply make the sides of the hub straight instead of tapered. Pewe said that there was plenty of material there to machine, and strength was not compromised by any significant amount. Once it was possible to slide the rim on, the hub was redrilled for 5 on 5.5 (one of the original lug stud holes must be welded closed first, as there is an overlap), new studs were installed, and the job was done.

So supposedly this is a fairly straight-forward modification that you should be able to have your local machine shop do for you, if not do it yourself.

PM me if you want me to get you in touch with this friend that's doing the 5-5-5 conversion. I'm sure he can explain better than I.

http://www.pirate4x4.com/forum/showthread.php?s=&threadid=11938