Turn on subtitles/CC's if you'd like explanations on what I'm doing throughout the video.
Videos on the 1-ton front axle swap:
https://youtu.be/YrAp5gWwtWU
https://youtu.be/mlaYSfEr7mw
This is my 1983 F250. Last summer I replaced the front- axle Dana 44 TTB with a straight axle Dana 60. Now I've gotten around to upgrading the rear Dana 60 with a Sterling 10.25. The Dana 60 was an open differential and it sounded as though the pinion bearings were failing. I found this Sterling for $200 out of a '92 F350, I re-geared it and installed an Eaton Truetrac limited slip differential, I also handled some other maintenance between axle and the truck itself. My F250 how has 1 ton axles front and rear. I kind of wish I just bought an F350 to start with, and maybe one that was less rusty.
Chapters:
00:00 - Disassembly
06:17 - New, broken parts.
08:32 - Replacing the pinion bearing races
12:04 - Installing bearings on the new differential
13:38 - Installing the ring gear
16:11 - Making a setup-bearing
17:36 - Setting pinion depth/marking the gears
25:28 - Setting backlash
29:29 - Final Installation
30:33 - How to press bearings without a press
31:35 - Final Installation continued
35:13 - Replacing brakes and hub seals
46:08 - Installing axles, diff cover, fluid
48:53 - Cleaning and Painting
50:55 - Moving all my vehicles when its -8 F/-22 C outside.
54:25 - Removing the Dana 60
1:02:37 - Swapping a couple parts over to the Sterling
1:04:21 - Installing the Sterling 10.25
1:06:35 - Making a spring plate
1:10:50 - Installing the Sterling continued
1:15:02 - Making a brake line
1:18:05 - Replacing the gas tank
1:22:12 - Wheels on
1:23:03 - Getting the driveshaft shortened
1:26:40 - Going out for some off-roading
1:31:47 - Cat