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Old 04-05-2012, 11:36 AM   #1 (permalink)
jtr
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1997 F350 Powerstoke dually 2wd to 4wd

My family is growing and I wanted an expidetion/tow rig. A new truck was not in the budget and I really did not like the new stuff anyway. Cummis was my first choice but the extra cab was not going to cut it with two kids.

My neighbor scrapped a F350 and had a KP 60 for sale, with tax returns coming I knew it would sell fast so I picked it up for $900. Next order of business was to find a mid 90's crew cab powerstroke 2wd. Took a few months but finally located a truck in Libby, Montana. Luckily my dad lives a few miles away and looked at it for me. Owner was asking $5500, I got it for $4000. Gave the old man $300 to drive it down to me and now its a project.

Original status
*6700 lbs with 38 gallons of fuel - no driver
*219,000 on it when it arrived
*Front bumper mangled
*Passenger rear dually fender crushed
*Lund Visor removed and holes filled with sheet metal screws
*Driver Door bushings were worn
*Tires are toast
*Aftermarket down pipe
*All major systems seem to be operational
*Trailer wiring tapped here and there - fixed it
*Goose neck hitch

As it sits today
*7100 lbs with 57 gallons of fuel
*King Pin 60 front with dually hubs, new joints, king pin rebuild, gusseted knuckles
*Rebuilt rear axle, Yukon Gears, New bearings through out
*New F350 leaf springs with 3" Sky Manufacturing Shackle Reversal
*Factory Dodge Cummins 4 inch rear blocks
*235/85 r 16s - Tread Wright re-caps in the rear - New Goodyear Duratrac fronts
*Boost, tranny temp, Pyro
*Replaced passenger dually fender with new JC Whitney replacement
*Stock diesel front bumper - used
*Rear portion of 4x4 E40d - Stock 2wd tail shaft - Pathfinder Van adapter - NP205
*MPG = 13.88 @ 70+ MPH empty
*MPG = 15.74 @ 60 MPH
*3 inch Super Duty intakes
*Wicked Wheel 2 compressor wheel
*7.3 inter cooler
*Home made bellowed up pipes
*CCV dump under the frame

From the CL ad









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1997 F350 Powerstroke dually, 4wd conversion, KP60, NP205
1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60

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Old 04-05-2012, 11:51 AM   #2 (permalink)
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Pics after my dad picked it up.





Dually hubs from Extreme Axel Sales, good company.



Used 4.10 gears from Mr. Mindless, great guy to deal with.



Little hammerd Krylon paint on the knuckles

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1990 Ranger 393w, C6, 60/14, full hydro, 4 link rear, H1s
1997 F350 Powerstroke dually, 4wd conversion, KP60, NP205
1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60

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Old 04-05-2012, 11:53 AM   #3 (permalink)
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Tread Wright tires



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1990 Ranger 393w, C6, 60/14, full hydro, 4 link rear, H1s
1997 F350 Powerstroke dually, 4wd conversion, KP60, NP205
1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60

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Old 04-05-2012, 01:34 PM   #4 (permalink)
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idk how it is out there, but that truck is mint for that mileage.

lookin good.
i'm kinda partial to the crew cabs
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Old 04-05-2012, 03:52 PM   #5 (permalink)
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Looks like a good start. I would just find a good condition 4x4 E4OD and forget dicking with a tailshaft swap. You have to tear down the entire transmission to swap output shafts anyways.
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Old 04-05-2012, 05:06 PM   #6 (permalink)
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Looks like a good start. I would just find a good condition 4x4 E4OD and forget dicking with a tailshaft swap. You have to tear down the entire transmission to swap output shafts anyways.
No plans on swapping the tail shaft. This is the back of a E40D out of a Pathfinder 4x4 van conversion. Looks like a factory 4x4 output housing and a custom adapter. The adapter is about 6" long, it should turn a 2wd transmission into a 4x4 version.





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1990 Ranger 393w, C6, 60/14, full hydro, 4 link rear, H1s
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1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60
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Old 04-06-2012, 07:20 AM   #7 (permalink)
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Drove it to work today, actually the first time I have driven the truck.

38 miles at 70 mph - 2400 RPM
Tranny temp 125*
Boost PSI was about 4
Went from 4000 ft to 6000 ft (pass) and the EGT peaked at 900* (no load)

Put the gauges in last weekend.

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1990 Ranger 393w, C6, 60/14, full hydro, 4 link rear, H1s
1997 F350 Powerstroke dually, 4wd conversion, KP60, NP205
1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60

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Old 04-06-2012, 11:01 AM   #8 (permalink)
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No plans on swapping the tail shaft. This is the back of a E40D out of a Pathfinder 4x4 van conversion. Looks like a factory 4x4 output housing and a custom adapter. The adapter is about 6" long, it should turn a 2wd transmission into a 4x4 version.
Interesting. I haven't seen anyone go that route before.
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Old 04-06-2012, 08:29 PM   #9 (permalink)
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looks really clean. I kept looking for intercooler piping and forgot the obs's never had one. I'd slap a zf5 in it and screw going with a e40d. Those trannies left a lot to be diseried not to mention rowing gears in a 7.3 is a lot more fun and your fuel milage would go up as well.
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Old 04-06-2012, 08:49 PM   #10 (permalink)
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looks really clean. I kept looking for intercooler piping and forgot the obs's never had one. I'd slap a zf5 in it and screw going with a e40d. Those trannies left a lot to be diseried not to mention rowing gears in a 7.3 is a lot more fun and your fuel milage would go up as well.
If I had one it might be an option, right now I will bolt a t-case to the back of the tranny and run it. The transmission shifts FIRM which leads me to believe someone has been in the valve body. Maybe it will live a long happy life with a good cooler and gauge.
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Old 04-06-2012, 09:57 PM   #11 (permalink)
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Consider that cooler an absolute necessity.
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Old 04-20-2012, 07:27 AM   #12 (permalink)
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Went to Pick and Pull and got a new instrument panel moulding. It came from a gas truck so I had to cut out the diesel display with a die grinder.





NAPA was having a sale on air filters.



Original set up



A little dirty



FIL gave me some 4" driveline material, I made two 22.5* cuts and welded back together.



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1997 F350 Powerstroke dually, 4wd conversion, KP60, NP205
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Old 04-20-2012, 07:30 AM   #13 (permalink)
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I would put a Aftermarket air filter on your to do list. Those stock air boxes were known to leak and dust the turbos. Tymar or BHAP is the way to go on those. I can get you the filter part # if you need.
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05 Dodge free-spin conversion /forum/dodge/880388-my-diy-2005-dodge-dually-4x4-5-9l-free-spin-kit.html
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LS motors are like tampons....every VAG has one!
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Old 04-20-2012, 07:32 AM   #14 (permalink)
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Never mind. You JUST posted them
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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LS motors are like tampons....every VAG has one!
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Old 04-20-2012, 07:35 AM   #15 (permalink)
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I would put a Aftermarket air filter on your to do list. Those stock air boxes were known to leak and dust the turbos. Tymar or BHAP is the way to go on those. I can get you the filter part # if you need.
ummmmm









My buddy did this a few years ago. I think he did a build up on our club board, Ill see if its still there.
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Old 04-20-2012, 08:31 PM   #16 (permalink)
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Thanks Tyson, Fat girl weighed in a 6700 lbs today. That is two full tanks of fuel and no driver.
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Old 04-21-2012, 03:31 PM   #17 (permalink)
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Thanks Tyson, Fat girl weighed in a 6700 lbs today. That is two full tanks of fuel and no driver.
That light? My 99 7.3, regular cab, 4x4 dually with a flatbed is 8100, been weighed by a scrapyard and a limestone place. My bed isn't that heavy either, 2 guys can pick it up if we're not moving it far.
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Old 04-21-2012, 04:39 PM   #18 (permalink)
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That light? My 99 7.3, regular cab, 4x4 dually with a flatbed is 8100, been weighed by a scrapyard and a limestone place. My bed isn't that heavy either, 2 guys can pick it up if we're not moving it far.
Boxed frame, intercooler piping, the fact that it is a 4x4 and his isnt yet (front leaves, axle, t-case, driveshaft, etc) and a handful of other things contribute. How big are your tires? Steel or aluminum wheels?
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Old 04-22-2012, 10:26 AM   #19 (permalink)
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Nice rig, love the OBS Fords. I had a 1997 Powerstroke extended cab shortbed that was supposed to get a Dana 60 pack in 02. Loved the truck, but sold it to fund the SAS on my Taco.
Anyway this guy just posted some stuff you might need:
/forum/axles-tires-wheels-sale/1061061-obs-ford-suspension-parts.html
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[url]http://www.pirate4x4.com/forum/showthread.php?t=850288[/url]
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Old 04-22-2012, 10:32 AM   #20 (permalink)
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1997 F350 Powerstoke dually 2wd to 4wd

I would steer far far away from the recap idea man. They cost less but will not hold up. That's personal opinion and experience but other than that I like your start.
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Old 04-23-2012, 07:52 AM   #21 (permalink)
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I would steer far far away from the recap idea man. They cost less but will not hold up. That's personal opinion and experience but other than that I like your start.
You might look into Tread Wrights reputation. There are lots of reviews of them over in the tow rig section. Recaps aren't what they used to be, and Tread Wright seems to be a very stand up company that stands behind their product. I have a set with 10k on them and they are holding up great!
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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LS motors are like tampons....every VAG has one!
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Old 04-23-2012, 05:26 PM   #22 (permalink)
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Boxed frame, intercooler piping, the fact that it is a 4x4 and his isnt yet (front leaves, axle, t-case, driveshaft, etc) and a handful of other things contribute. How big are your tires? Steel or aluminum wheels?
Stock sized tires, aluminum wheels except for the inside duals. I just didn't think I'd be that much heavier, especially since he has a 4 door and mine is a regular cab. Intercooler is light, most of my frame isn't boxed IIRC, and shorter at that. Axle and transfer case add weight of course, just didn't thing it would be that big of a difference.
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Old 04-23-2012, 05:31 PM   #23 (permalink)
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I would steer far far away from the recap idea man. They cost less but will not hold up. That's personal opinion and experience but other than that I like your start.
I run recaps on my dually with no problem, and my truck is 1400 lbs heavier if both of our scales were accurate. Heck I run them on everything I own that the correct size is offered. Lincoln Town Car, my girlfriend's explorer, and my dually. A friend wheels recaps on his Samurai, airs down to maybe 8 then drives it home at the end of the day, hasn't lost one yet.
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Old 04-23-2012, 06:59 PM   #24 (permalink)
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Nice rig, love the OBS Fords. I had a 1997 Powerstroke extended cab shortbed that was supposed to get a Dana 60 pack in 02. Loved the truck, but sold it to fund the SAS on my Taco.
Anyway this guy just posted some stuff you might need:
http://www.pirate4x4.com/forum/showthread.php?t=1061061
Hey Jake, thanks for the link. I read that the F250 springs are too stiff for a solid axel setup? Could use the rear blocks though.

EDIT: I looked into the spring rates on the F-250s and F-350. According to SDtrucksprings.com there are many options for the OBS Ford.

Part number-----OEM--------------------------------Spring capacity------Application
43-516----------E5TZ5310K-------------------------2200 lbs--------------F-350
43-476----------E0TZ5310R/E0TA5310ABA--------2575 lbs--------------F-250 and F-350
43-478----------E0TZ5310S/E0TA5310ACAA-------2755 lbs-------------F-250 and F-350
43-498----------E3TZ5310R/E3TA5310ABA--------3486 lbs--------------F-250 and F-350

For reference, the hot ticket SuperDuty V code springs have a spring capacity of 2230 lbs.
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1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60

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Old 05-05-2012, 07:04 AM   #25 (permalink)
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Been fixing some little things this week. The passenger rear window would go the opposite direction of the switch.

Checked the voltage at the driver or main control and all switches had matching voltage up/down in the respective positions. I assumed the wiring was correct there. The connectors in the door are keyed so I assumed they were correct. The only explanation is that someone replaced the window motor and when it was built, the wires were soldered incorrectly. With that, I pushed the wires out of the plastic connecter with a pick and swapped the wires. Now all windows work as they should.

Driver door would not unlock with the key. I popped the clip and removed the tumbler, sprayed it out with carb cleaner, and blew it out with some compressed air. Checked with the key and it works again, put it back in and tested with success.

Little things like that drive me nuts so it nice to make some forward progress..
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1990 Ranger 393w, C6, 60/14, full hydro, 4 link rear, H1s
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1965 Chevy 1969 4x4 frame, step side, daily driver, TBI 350, TH350, 205, D44, D60
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