O.K., after 260,000 miles my front end needs some work. New wheel bearings, all ball joints, and disconnect repair. Grand total is over $600 just in parts, for a $500 truck (what I paid a year and a half ago). It also needs another new track bar (3rd new one in 1.5 years).

I have a part's truck that I pulled the engine out of for my Dakota project (5.7 Hemi), and have the rolling chassis left over (and most of the rest of the truck). That truck, a 2004 Ram 2500, I was surprised to find, uses the same front axle for the 2500 gas engine as for the 2500 diesel and 3500 trucks. At least it seems it according to the Dodge part's site I looked on, that showed the same front axle parts for the 2500 and 3500 trucks.

Now the question is, how is the strength of the 9.25" AAM compared to my Dana 60? I don't severely abuse the truck, other than hauling heavy loads from time to time, so I would think the axle would do me fine. I'm keeping my eyes open for a kingpin Dana 60 from a Ford, so the AAM would be temporary. And because it has no disconnect, my 4x4 will be back working again!

Next question- the suspension looks the same...but as anyone tried swapping the front axles between these trucks to see if everything bolts up? I'd like to be aware of any surprises in advance. I already know the pinion yoke is different.

Jim

 

I thought the ford dana 60 had leaf springs instead of coil. I know my 96 F250 pstroke did. And the steering linkage would more than likely be different. If you find one and it works let us know. I would love to get rid of my ball joints, living in the country on gravel roads eats them up!

 

The Fords do have leafs- another bonus for using their axle. With our rough roads, it would be nice to have a more durable front suspension. No more replacing track bars every few months, sway bar links just as often, and Rams in this area need control arm bushings every couple years. I like the way the Fords ride on our roads- much more stable than the Rams.

Jim

 

i like the aam axle better my self, but theres not a whole lot of parts out there for them yet. it should bolt right up all the mounts are the same, but you will have to get a driveshaft made with the new style yoke, and i think the fittings and the brake lines are different but i'm not positvie.

 

Thanks! I looked at the driveshafts, and I think I can put the flange from the '04 driveshaft on the end of my shaft (have to check u-joints) so my shaft may work. I'm planning to use the '04 brake hoses and connect them to my existing lines. I have the AAM axle all unbolted, hopefully I'll have it out of the truck tomorrow. If I get time maybe I'll swap them Sunday. While I'm at it I may cut the track bar off the '04 frame and weld it to my '96 frame so I can use the '04 track bar. NO MORE LOOSE JOINTS! Of course right after I get it installed I'll probably come across a cheap Ford Dana 60...

Jim

 

don't bother cutting the tracbar off the old one pick you up one of these, its the best you can buy for dodges.http://thurenfabrication.com/stocktb.html here is the link to his site he makes possbly the best trac bar and crossover steering for dodgeshttp://thurenfabrication.com/

 

So a 3rd gen 9.25 axle will bolt right into a 2nd gen that came with a dana 60? Man, I would have never suspected that, since the frames are different and all. How in the HELL did you find a running 4x4 dodge with a cummins in it for $500? I have a '96 extended cab long bed 2500 4x4 I bought that runs, but it's a 5 speed and I paid $1500 for it. I feel like I stole it, too.


Oh, on strength-there's a 1/2" difference in ring gear diameter between the dana 60 and the aam. However, ring gear diameter is not the only predictor of axle strength. Furthermore, from what I hear, the cad stuff on the dana 60s is problematic. This being the case, I'd venture to say you will not have any trouble with the 9.25 being weak. Remember, they put them in the current 2500s and 3500s, which make far more power and torque stock than any 2nd gen did.

 

Check out my Photos section for why it was $500.

I have the 9.25 bolted in place today. There were some issues, this definately isn't a bolt-in swap, but it can be done with a little fab experience. This is what I have found so far:

-Sway bar brackets are different. The '04 has the same exact sway bar links, but they are mounted upside down because of the difference in brackets. The '04 has the same style mount on the axle that the '96 has on the sway bar itself. I was able to cut the sway bar brackets off the '96 axle and put them on the '04.
-Track bar is a different length. This removed any possibility of reusing my '96 bar on the '04 axle (also, I wouldn't be able to use the aftermarket kits) because the axle-end mount is in a different location. I'll be welding the '04 mount onto the '96 frame tomorrow.
-Frame width is slightly different. This caused the control arms to not quite line up. They were close enough that I could get them in place easily by hand, so they should be fine. I used the '04 control arms.
-Control arm bushing sizes are different. I had to drill out the upper bolt holes to 9/16" abd the lower holes to 5/8" on the frame brackets. The '04 upper bolt length is different as well, but my original '96 lower bolts worked in the upper holes, and the '04 bolts fit the lower holes fine.
-Driveshaft is different because of the drive flange on the '04 axle, but I think the '04 driveshaft will bolt in place. I'll know tomorrow.
-'04 brake hoses use a different thread than the '96, so I'll get adapter fittings for them. Also, the '96 has a tee built into the driver's side hose, the '04 has a completely seperate line. I'll just install a tee.

-The spring pockets and shock mounts line right up, and the spring pockets are the right size.
-The axle is a hair wider, but close enough that it looks fine under the truck.
-Remember that you better get the wheels that came with the newer axles. 16" wheels won't work with the larger brakes. I have the 17" wheels from the '04, so I'll use those. Bummer though, I had a couple brand new tires for my old wheels.

I'm planning to use the rear AAM that came in the '04 as well. I'll need to move the spring pads, but thats minor. The front axle has 3.73 gears, and my truck came with 3.54. I know this axle isn't as strong as I'd like with a diesel, but I'll be watching for a set of axles to swap in at some future point. At least with these axles, I won't be in a hurry, and can concentrate on my transmission swap. The bonus is that I'll get rear disks with the new axle.

Jim

 

SOunds good man, glad you got it in. I never would have guessed it would have been that easy!

 

I test drove it yesterday, and WOW! What an increase in braking! The larger brakes on the AAM axle do wonders for stopping this thing! This morning I swapped in the matching AAM rear, I just have to put a metric fitting on the brake line and bleed them, and test drive it. I think the new 3.73 gears will be kind of nice for the local driving I do most of the time. I had 3.54 before, and they were great on the highway but I think the 3.73 will be a bit better around town. I can't wait to try the rear disk brakes! The rear required the spring pads to be moved inward about 2" on each side. I was able to put the driveshaft flange on my existing rear driveshaft, using my stock U-joint (same joints), and the length was perfect.

Jim

 

Sweet. You are piecing together one cool rig.

 

I had a reply show up in my e-mail, but it doesn't show here...asking about the wheel size. I'm using the 17" wheels that were on the '04. I tried a couple 16" wheels today, a single wheel and a Budd style dually. Neither one would clear the calipers on the rear. So I'm left with 17+ wheels as my only option.

More progress was made today. I got up this morning and since I didn't have to be anywhere until evening, I decided to do the rear axle swap. It was a breeze, as expected. I had to cut off the spring pads and move them inboard about 2" per side. The shock mounts were very slightly further outboard on the AAM axle than my '96, most likely because the frame rails are wider on the '04, but the shocks still bolted right in without a problem. I was able to use my stock '96 rear driveshaft and just install the flange from the '04 driveshaft. Both trucks use the same rear U-joints, so it went right on. I had to adapt the brake line to metric for the AAM axle, and I still need to do something about the parking brake cables. It shouldn't be difficult to hook them up, I just didn't have time today. I got it all installed, welded the spring pads on, and my test drive was a 180 mile run to the south end of the state. The truck drove like a new truck! As expected my RPMs were a bit higher on the interstate than with the 3.54 gears, but with our hilly country, I think I will average about the same MPG as before. I notice that the engine doesn't work nearly as hard on the bigger hills, the truck just cruises up them as if I was on flat ground.

The rear disks work sweeeet! I thought I had an improvement yesterday...that was nothing compared to today! I can't wait to get loaded uip and haul my 5000+ lb. load of wood home Saturday. Braking will be a pleasure!

Jim