I've got a good friend that's looking at swapping a 3rd gen 9.25 disc brake rear into his '96 Ram 1500 2WD truck. He wants to use the 3rd gen rear for 3 things - limited slip unit's in it (no limited slip in the old rear), 3.92 gearing (instead of 3.55 gearing in the old rear) and disc brakes (instead of drum brakes). He's already noticed that he will have to weld on new spring perches, as the 3rd gen rear's spring perches are further inward on the rear on each side. He may also have to use larger diameter wheels unless he can create enough clearance by grinding a bit off the calipers. He will also need to use the '96 speed sensor on the 3rd gen rear.

Has anyone performed this swap successfully? If so, what else might have to be considered to make this swap work properly?

 

I think there is a thread about just this swap somewhere around here.... it's been in the last couple years....

 

Well, I did a search and didn't find any comprehensive thread about a 3rd gen to 2nd gen 9.25 disc brake rear swap. If you happen to see one out there, please link it into this thread. I've gleaned a few tips via YouTube, but nothing out there showing a full step by step of what was done to make the swap work. As I work with my friend on his swap, I'll come back here occasionally to post what was done to make the swap work successfully.

 

Well, need to concern yourself with the spring perches, possibly shock mounts, brake lines, and e-brake cables. A lot of that you should be able to get with the replacement axle. Dodge changed the way the rear driveshaft connected to the rear diff as well... but, that's a pretty minor issue. Yoke from your old rear should bolt right up to the new one.

 

Yes, I found out about the spring perches the hard way. Saw a YouTube video of a guy welding on new perches. My friend got everything with the rear, including the parking brake cables and the driveshaft with the rear end connecting flange & u-joint out of the 3rd gen truck. He really wants to use his existing 16" wheels with the swap (since he bought new tires recently), so he's hoping that he can make them work and not have to use larger diameter 3rd gen wheels. This project will take some time, as he's working on numerous other things right now..

 

Master cylinder/prop valve differences?

 

That shouldn't be an issue, but we'll see. For some perspective, I swapped the drum brake Dana 60 rear to a late model 2nd gen disc brake Dana 60 rear and re-used my existing master cylinder and prop valve. While there may be some differences, no issues were encountered with my swap.

 

I have both 2 and 3 Gen. I used axles from 2 Gen for 3 Gen. Can swap your internals from 3-2. Weld flanges for backing plates of disc brakes onto 2 Gen.No need to change driveshaft yoke. Need flanges move about 5/8 of an inch. Does not address Anti-Lock on older truck if you have it.
Relocate shock perches as well. Pretty sure.

 

Somewhat clear. Somewhat confusing. Cryptic little. Make sense maybe.

 

Interested in the results. I have been pondering this swap myself, possibly posted about it in one of my build threads, and maybe that's what your memory is thinking of, but getting solid running engine/trans is goal one. Axle swap later