Hi all, I'm new to the forum (obviously) but have owned Dodge trucks for some time. My name is Matt and I live in southern AB, Canada.

I have a 06 2500 Diesel Mega cab 4x4. I use this for all my heavy hauling and is bone stock apart from a topper and 285/70R17 tyres.

Also have just recently picked up an ex-city utility 93 W250 5.9L gas regular cab, long box at auction for $600.

Last but certainly not least is battered and trusty 76 W100 Power Wagon RC/LB that I use as a general farm hack, parts runner, hauling crap to the dump and snow plough. It is the most useful truck I have ever owned and it only cost me $360.......and it came with $60 worth of gas in the tank!

So I have a question about the 1993 5.9L gas W250. Are they any good off road? By off road I mean trails not rock crawling or mud boggin. I know it is a big beast and tight trails will be a problem but I have a plan for that so apart from the stupid CAD (that already is giving me problems) what other running gear or chassis items should be upgraded? I'm thinking of running a 37" MT tyre, Detroit lockers and no or as little lift as possible. The bodywork will not be a problem.

Cheers,
Matt.

 

I don't think you'll clear 37s with any sort of small lift. You might want a few skid plates. I don't know how the 4x4 is set up, but on the 2wd version, the transmission is exposed. As a result, my pan is dented.

 

Thanks for the reply. I have a crazy plan as far as bodywork is concerned (the body is being swapped for a 1961 Land Rover Series II 109" hard top) so any lift will have to be somewhat custom anyway.

My Dodge has the Dana 44 front axle with the CAD, how strong would that be? I have heard that a 35" tyre would be a more sensible size with this axle. Also, I assume I have a NP208 T'case? How are these for durability?

Thanks,
Matt.

 

Sounds like you are building a hard core off roader. The entire drive train in your 93 was never intended to take the torque needed for 37 inch tires. I would suggest getting away from any axles with C-clip retainers and I would also get away from any T-case with a chain. JMHO

 

If it is a w250 you should have a D60 rear axle (it is possible to have an HD 9.25 but unlikely)

The D60 rear will be fine but you might think about going to 35-spline axles.

You will need a D60 front - dodge ones cost as much as gold but a chevy one can be used but you will need to "bend" the springs in to fit the spring perches.

You probably have a 241 transfer case which has a lower range than a NP205 but as Seal alluded to, the 241 is aluminum housing with chain drive. They are a very good case but for serious off-roading you will proably break it so find an NP205.

 

For my education. Would you tell me why he should have a D60 and not a 9.25? I don't think the 44 was used in the heavy 3/4 tons that had the D60. I could be wrong here but I am always willing to learn.

 

My 93 W250 is a plain Jane RC/LB with very few options. I have the old 360, injected and I assume the 727 auto with NP241 T'case. A D60 lives in the rear with a D44 CAD up front. It currently has 265/75R16 tyres (31.5").

A pretty sturdy truck all in all I think. I had hoped with it's 3/4 ton rating and the installation of the light weight Land Rover body (they are mostly made from a material called 'Birmabright', a alloy of aluminium and magnesium) I would be OK running a 35" tyre on the stock running gear. Perhaps even a 37"?

I'm not looking to create a monster truck or indestructible tube type rock buggy with this project. I mostly wheel mountain trails and such and overland type camping. Obviously a D60 up front would be the ideal but up here in the frozen north the only 1st gen Dodge trucks I have seen with that axle are the Cummins Diesel trucks............and seeing as they never want to die and just keep on truckin finding suitable axles at a suitable price is difficult.

Is the chain drive NP241 T'case another weak link then? As far as I know they are aluminium cased with a planetary low range, correct? I would like to keep as much of the truck mechanicals as 'stock' as possible for ease of maintenance and repair. Would a gear driven NP205 swap be worth it?


Thanks for all the help so far guys,

Matt.

 

8-Lug 9.25's are a rarity but they do exist and were "light-duty" and a poor choice overall for anyone going off-road.

3/4 ton trucks could come with a 3500lb (D44) front axle and would have the NP241
4500lb (D60) front axles were found in some 3/4 ton and all 1-ton trucks and had the NP205 transfer cases.

Diesel trucks (auto trans) have the D61\D71 axle combo due to the higher gear ratios used (3.07 and 3.54's) The D61\71 is not a sought after axle combination due to a lack of support and a special ring gear spacer needed to re-gear.

 

In a 1993 you should have the A518 (overdrive) trans and yes the 241 transfer case.

There is nothing wrong with the 241 - and if your not beating on it it will hold up fine...IMHO I feel your D44 front axle is the weak-link. Yes you could spend big money for alloy axles etc but you would be further ahead with D60 even stock.

If you swapped to a NP205 it would bolt right onto your transmission but you would need to either find the correct length drive shafts or have your modified.

You can check www.car-part.com in your area for axles and transfer cases.

 

That's great, just the kind info I need. I had given some thought to replacing the two piece shaft in the front axle with a aftermarket one piece, but the general collective wisdom on this is that it is better to spend the money on a D60 swap.

Thanks for the help.

Matt.