Axle Swap- Turning my 1500 into a 2500
 

I'm getting ready to turn my 1999 1500 into a 2500 with parts from a 1996 and I understand swapping the front axle is no problem and everything fits. I was originally told the back would bolt right in too, but I found a few people that said it will not and that the U-bolts don't match up. I am swapping the 2.5in leafs for 3in also, will this fix the issue? Another thing I thought would be fine is the drive shaft. Will the shaft from my 1500 work, if not can I just use a 2500 shaft? Last thing someone mentioned is the gear ratios, I am assuming my 1500 and a regular V8 2500 will both have 3:55 gears, am I right about this? Is there anything else that may be an issue between a 96 and 99? Thanks for the help!

Since you are swaping leafs to the 3in you will need new Ubolts. Gear ratio could be 3.55,3.73or 4.10. Just make sure the front and the rear are the same lol... Your drive shaft from your 2500 will slip into your trans as long as both trucks were autos. The length im not to sure on if anything it will be an inch or two off if at all.

U bolts are designed to stretch a little when you install them. Most of them instruct you to torque them down, then do it again after about 1000 miles. Because of this it's not a good idea to re-use them. You should be getting new U bolts anyway.

Curious about the rear axle as well. I've read alot of things that say you need to cut off the rear perches and weld on new ones because there is an inch width difference between the 1500 and 2500. However Extreme 4x4 did and episode where they swapped a D60 front and rear out of a 2500 into their same year half ton and said there was NO fabrication needed and it was a direct bolt on. I realize they could easily be full of it being tv and all, but can someone clarify this?

the 3/4 tons do indeed have wider springs. you could probably just bolt the d60's to the stock 1/2 ton springs, but, in my book, that isn't doing it 'right'.

I have a 01 1500. I put a 94 gas 2500 rear 60 in. I did not have to touch a thing. Direct bolt on for me. Now other people have come on here and said they had to move there purches. So i guess it just depends. And yes the front axle is a bolt in.

@HeyYou
I understand that if you don't want to re-weld the perches you can notch the existing ones to use the u-bolts on the half ton. This seems to be a common thing from what I've researched. Please elaborate if I am wrong.

@Kraiger
Thanks for clearing that up. I suppose an easy thing for me to do would be to measure. I know my perches are 42in inside to inside. I just haven't put much effort into it because I don't weld and there seemed to be a lot of conflicting reports. My truck is a 2000 Sport Off-Road so I assume that my situation would be identical to yours? That is confidence inspiring because it is an upgrade that I really want to do. The benefits are too much to ignore.

I apologize to the OP for thread jacking.

Thanks guys!

Thanks for the posts. So if I swap the springs too, that should take care of the 1in difference since the .5in in each spring adds up to 1in? Thanks

@Turbine: that should work. :D

@eggie: if you swap the springs as well, you will need to swap the spring hangars as well. (on the frame)

So... New problem! The drive shaft on my 1500 is 5 1/2 in longer that the on on the 2500. I haven't hear of anyone with this issue yet...

yeah your drive shaft will be differant. If you messure both axles from back of pig to front yoke there is a differance. sorry i didnt say that before.

Kraiger did you have to weld a different yoke onto your driveshaft for the bigger u-joint associated with the D60?

No i didnt. I ran a combo U-joint for a while untill i had a new driveshaft made. ( if you dont know what a combo joint is, two caps are one size and the other caps are the other size).... My local clutch and joint shop and spicer dealer had the right one.

i think 94-95 (LD) 2500 had 2.5'' springs, all 95-02 (HD) 2500 had 3'' rear springs.

hope this clears thing up a little for you.

also 2000+ d60's have rear disc brakes, 2001+ d60's have dual front piston calipers. very few late model 2002's recieved AAM axles

^ all that is for 2500-3500 dodge trucks.


ive been researching this for awhile, i want to make a little POWER WAGON!

Kraiger- So how did you solve your drive shaft problem until you go one made? I know the 3/4 ton's drive shaft should go right into my transfer case so if I take the axle and drive shaft everything should work?

As long as they are both autos then yes the 2500 should work....now im NOT 100% sure on that but it should because its built for the longer D60 rear housing. Also make sure both trucks are the same cab and bed length. If not then the shaft will not work.

So I bought a 97 2500 to do my swap as well. What is some insight on using stock 1500 drive shafts, but modified yokes to work. It would be nice to just swap the transfer case, but I fear input shafts are different. Could I junkyard search 2500 ext cab driveshaft and be done? Parts truck is a 5.9 as well. It would be sweet if I could swap transmission and transfer case, but I'm not exact about adding in the 98 electronics to the older tranny.

I am gonna be curious as how much extra lift I'm going to get with the helper springs. All the perches, helper spring stops and all, I was planning on unbolting and bolting up to the 1500 frame.


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