I know this seems a long shot, but I have been known to do things the hard way (aka 4x4 swap on a 4x2 94 Explorer) and I am wondering what it would take to make my 1500 a mega hauler. I have a 1998 Ford Explorer lifted with 33's and I am planning on running it at moab next year. Since distance is a bit of a factor (I am in Houston) I want to maximize my chances of getting it back even with a severe breakage issue (Hey, hope for the best, plan for the worst).

Now the truck I have is a 1998 Dodge Ram 1500 ST with the 5.2 2wd single cab long bed. Now I am very comfortable with this truck as it has been very good to me, but I know that I am going to be pushing the towing capacity of the truck and I am very afraid of the fragile auto trans in these trucks going kaboom at the wrong time.

Here are my thoughts, check me if I'm wrong. First off I figure that the 2wd 2500's front suspension parts are still IFS but beefed up (stronger A arms, spindles and stiffer coil springs) so I'm wondering if the upgrades would be a direct swap? I also want to throw the D60 rear end in with the 3 in leafs (dually would be nice, but its not a deal breaker) and upgrade to the 5.9 with a manual transmission. Are these feasible upgrades, or am I just blowing smoke?

Thanks

 

After some quick research I have narrowed down the main differences between the 2500 IFS and the 1500 IFS.

Calipers
Rotors
Coil Springs
Lower Control Arms

Not confirmed but probably the spindle as well

Rear suspension

Leaf Springs 3" vs 2 1/2"
Leaf Spring Hangers
Leaf Spring Mounts
U bolts
D-60

So not really that bad. The hard stuff will be getting the 5.9 in and finding a manual transmission.

 

Your original drive shaft won't work with a d60 either. Some modding will be needed(no biggie there). Anyway, the tranny is the weak point, and 2500's use the same 46re. Better off upgrading the rear suspension with helper springs and maybe some Timbrens or air bags. And putting better gears in the rear end or even a locker. Adding an aftermarket tranny cooler and a temp gauge and removing the check valve will help with the tranny. And don't tow with OD on. Also one of them trailer hitch weight distribution attachments too. You can also upgrade your rear wheel cylinders to one ton GM WC's for better braking. I also think you can upgrade the front calipers to dual piston, along with replacing some other parts to make them fit.

 

I did notice that the 2500 lower control arms were much beefier than the 1500's. Also coil springs and leaf springs would make a big difference in how the truck rides. I guess since this towing thing is just once in a while, I think I can scale back a bit in my plans. Most of the time I'll drive her empty, anyway.

But manual transmission is a definite upgrade. Auto's have always been a weak point in any drive line and I prefer a direct engagement when I am towing something.

 

^^^ Make sure you grab a cast iron cased NV4500 out of a 2500, not the aluminum cased little brother NV3500 from a 1500. Since you are going for strength.