They put spacers on the front and fenders on the rear. This keeps from having sharp bends in the cable housing. The last pic shows the adjustable connection finalized. The outside weld is then added for assurance. With the new calipers and van E-brake system we had to use the van's E-brake cables. I did not have fancy tools or facilities so it make for some dirty days.
The unique style of the Ford F350 Super Duty professional grade trucks provide a great platform for an aftermarket suspension lift kit. So our initial guess was that we were just going to take the Sawzall and cut the weld off which would free the D60 flange. Increased front carrying capacity isn't needed when you're towing a trailer plus in most places, an F-250 is cheaper to annually register than an F-350. To do this we needed a way to adjust the distance between the pedal cable and the equalizer bar. Not having to buy wheel adapters saved us an arm and leg, not to mention the junkyards in our area are full of vans, not Super Duties. Not that it makes huge difference but both actually had F-250 Badges. This is to show that with time and dedication you still can keep your project going, just gotta keep the final product in sight, cant forget budgeting lots of budgeting.
This means it will be easier to set the new flange perpendicular to the tube and keep the brake calipers in alignment over the rotor. Now you should be ready to tack weld making sure the heat doesn't pull the flange too far out of alignment. Ok so then the outside weld blob is machined off, then the flange is placed over the tube while glowing red hot and allowed to shrink as it cools on the tube offering an extremely strong fit. Well I wish you good luck on your project and do not get to intimidated by the project, just stay ambitious. It took a few hours and I was alone. The only thing possible is to just machine it off and then bore out the hole to exactly or a few thousandths over 3. This would save you from ruining a good axle housing like we did.
The conversion kit will come with all the pieces need to complete the job, wheel packages are also available. A little grinding on the E-brake shoes and it fit, but without the return springs. Make sure you get the axle lined up with the rear. For the top row pics, the first two are under tension E brakes applied and the third is with brakes released. This is something that I have never seen anyone post on youtube.
A tab was fabricated and welded on the axle tube to hold both the solid and flex lines securely. The length of that truck combined with its width made it the most stable towing truck I've ever had. We plan on checking the Ford dealer again to see if a 1999 van had them, and if so make the purchase and install them at a later time. Watch project and hobbie sit on back burners till more money saved up and everything back on track. Finished photos of the rear disc conversion. When there is no force on the pedal the cable is still under spring tension pulling it from the rear axle. The installer-friendly Revtek lift kits for your F250, F350 Super Duty include custom designed front leaf springs to significantly improve ride quality.
. I've been looking on youtube way too long for a tutorial, so I think I'll do my own. We then pulled the pedal cable taunt but not enough to move the cable and used the adjustment on the rod to take up the slack from the E brakes. The diesel motor was toast but everything else is good. Comments on this setup: as you can see, this is a lot of work, and is probably not a weekend job. I was able to take mine to the alignment shop and it was in good shape.
Also the hub area was built up the same way. The left side of the truck is different and will not work on the van. Pic 5 shows the left side cable routed along the side of the frame and over the spring hanger, but not through it as was done originally. Before we cut or machined anything we carefully referenced the angle of each caliper bracket so that they could be duplicated later on the Sterling axle. Try to get a truck that is close to what you have to make life easier. Really the hardest part is over because when you see the size of the flange on the Sterling and how easy it is to remove, you're gonna laugh.
Very time consuming takes a week if you are properly equipped with tools and lift etc. Can be used with 1999-2015 E-Series with X45333 5. Part 2: So now your bench should look something like this if you have already collected all the parts from your nearest auto parts store, or online: The Sterling axles have a neat oil seal unlike the Danas. We did have to cut one tack weld since it pulled in too much. It won't know the difference between drums or discs.
The Russell fittings were used to tie the braided lines to the hard lines. Note: the new spring had to be shortened by rebending one end. Again like everything stated In the video, this is a work in progress build like any other typical person would have to do. The solution: shorten the long one by cutting the cable and making a new barrel end. Now with the Dana 60 home we inspected it again to make sure all was well. Pic three shows the modifications to the end of the left side cable housing. I also strongly suggest reinforcing the frame where the shackle bolt goes through the frame.
True the Super Duties have five, but the pedal feel of the '97 got a little more spongy. I have also seen the 250 drw's and it was the same deal, just conversion trucks. We did not actually use the method in pic 3 to below to crimp the barrel on the cable. A 4in Lift Kit by Rough Country is the main reason of the video. The inner piece will mount on two of the axle flange studs and the third mount attaches to the caliper bracket bolt for a sturdy support. Big foot is right, until 99 ford did not make a 4x4 drw truck.