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2500 4x4 frontend rebuild

Old Aug 5, 2022 | 10:10 AM
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Default 2500 4x4 frontend rebuild

I will be dropping my front axle and would like to replace all bushing items.
Does anyone have good or bad experience with specific brands of replacement parts?

I would also like to replace my steering box, what is the recommended?

Also at the same time I will be replace my front main seal.

I'm not a guy that needs top performance, just want good quality parts.

I'm really looking forward to you responses.

Thank You,
 
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Old Aug 5, 2022 | 11:10 AM
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You want to do a front end rebuild and just replace bushing items? There are quite a few moving parts in the front end associated with the axle. I'd suggest replacing the problematic 2nd gen track bar with a 3rd gen style track bar. I used the Solid Steel adjustable bar and conversion bracket. It has poly bushings in it and will likely outlast the truck. You can see information on it here - http://solidsteel.biz/trackbars.htm
As for the upper and lower ball joints, I went with McQuay-Norris units. Moog is also good. I also replaced all of the tie rod ends and drag link. I went with Spohn control arms, which have greaseable poly bushings in them. I've had no issue with them. You can see those here - https://www.spohn.net/shop/1994-1999...2500-3500.html
I use Rancho 7000 shocks, however, others tend to like Bilsteins. I replaced the wheel bearings and U-joints at the wheels. I went with budget parts here, but most like Timken bearings and Spicer U-joints. I replaced the sway bar links with poly bushings. As for steering gear box, I went with a Borgeson unit. Many have had mixed results with them, but mine has done well. They are hard to find now for the 2nd gen trucks. Might want to check out Red Head or Blue Top units.

Keep in mind that I experienced a really bad case of death wobble when I first purchased my truck used years ago, so I decided to rebuild the front end to last quite a while, since I don't plan to get rid of this truck anytime soon, in addition to eliminating death wobble from ever coming back again.
 

Last edited by AtomicDog; Aug 5, 2022 at 11:15 AM.
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Old Aug 6, 2022 | 11:09 AM
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I'd suggest replacing the problematic 2nd gen track bar with a 3rd gen style track bar.
Is seems the problem is with 1500's not so much the 2500's even though the use the same one. I still have the stock one with 230K(2500). it does have a slight bit of slop(no death wobble). Most of my other front end parts have been changed. if you plan on removing it replace everything and you won't have to worry about it failing in the near future. Make sure you get greasable parts they can come in non greasable and greasable. I used moog parts with the exception of the bearings and u joints. Don't skimp here! Get timken and spicer life(SPL) u joints. I have had these u joints in my truck for 170K with no issues(also greasable).

I would also like to replace my steering box, what is the recommended?
If it's only leaking and no major slop in it just reseal it. The problem with the ones you get today is the just reuse the worn parts(steering shaft). So you may or may not get one better than what you currently have.

Also at the same time I will be replace my front main seal.
If you are going that far you may want to replace the timing chain and water pump. Assuming you have over 100K. And dont forget about the plenum gasket issue.
 
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Old Aug 7, 2022 | 03:02 PM
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Originally Posted by Moparite
Is seems the problem is with 1500's not so much the 2500's even though the use the same one. I still have the stock one with 230K(2500). it does have a slight bit of slop(no death wobble). Most of my other front end parts have been changed. if you plan on removing it replace everything and you won't have to worry about it failing in the near future. Make sure you get greasable parts they can come in non greasable and greasable. I used moog parts with the exception of the bearings and u joints. Don't skimp here! Get timken and spicer life(SPL) u joints. I have had these u joints in my truck for 170K with no issues(also greasable).


If it's only leaking and no major slop in it just reseal it. The problem with the ones you get today is the just reuse the worn parts(steering shaft). So you may or may not get one better than what you currently have.


If you are going that far you may want to replace the timing chain and water pump. Assuming you have over 100K. And dont forget about the plenum gasket issue.

????And dont forget about the plenum gasket issue.

Not familiar
 
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Old Aug 7, 2022 | 03:38 PM
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Originally Posted by wrenchmaster
Not familiar
And so it begins....
 
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Old Aug 7, 2022 | 04:58 PM
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Originally Posted by Moonpie
And so it begins....
Sorry I haven't filled my signature... I have a diesel.
 
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Old Aug 8, 2022 | 02:52 PM
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Originally Posted by wrenchmaster
Sorry I haven't filled my signature... I have a diesel.
Then you don't need to worry about the plenum issue.
 
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Old Aug 8, 2022 | 11:47 PM
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Originally Posted by HeyYou
Then you don't need to worry about the plenum issue.
And so it ends!
 
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Old Aug 9, 2022 | 05:58 PM
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You have to worry about the killer dowel pin though unless you had the fix installed.
 
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