2000 b1500, 5.2L. Ok, I'll start by saying that this is silly. This is a 26 year old 5,000lb van. If I want better towing I should just get a used truck. Heck, maybe even something with a trailer brake controller. Still though, I am stupidly attached to dodge vans.

I'm also not well set up to regear myself as I have neither a lift nor a press. I might have a bearing pull kit somewhere but yeah, I would not be in for a good time. Shimming it would also be a lot of guess work unless there is some simple DIY method. So that leaves me with paying a shop to do it. I'm guessing that the price is what is going to make this stupid.

With that being said, anyone else do this on their van? Alternatively, how big of a job is it to swap a whole rear axle and diff in if I can find a factory 3.92?

Like I said, this is probably nonsense, but you only live once right?

 

It's actually cheaper/easier to swap the entire rear end, than it is to regear. Car-Part.com can likely help you find an axle with the correct gear ratio. Find one you want, then CALL the yard that has it. Email etc, just don't work that well there. Rear end swap can be done in your driveway, but, gotta have air tools. (either that, or REALLY strong. )

To regear, and pay a shop, you are likely looking at 1200 to 1500 bucks. Or more.... the parts ain't cheap, and it is NOT an "easy" job. Finding someone that knows what they are doing can be challenging as well. If there is a 4x4/Offroad shop nearby, that would be your best candidate.

 

Thanks. Pretty much confirming what I already suspected. We do have a decent gear shop nearby. One of a dying breed. Honestly, I'm approaching 40 and I'm a little worried about what is going to happen when all of the 60/70 year old guys retire/die. I was just talking to someone about my ABS module and how I googled electronics repair and there is nothing but smartphone cracked screen replacement places or computer shops that will just swap in new parts. They don't "repair" anything. Anyway, I was figuring $1300 or so, mostly because I suspect that they wouldn't just want to regear, they would want to do a full rebuild including axle bearings.

The air tools I actually have. The air supply, not so much. Somehow I doubt my little pancake compressor would be up to it. That or I see what my battery high torque can really do.

I'll look at car-part. I've yet to find one of these vans in my state (Oregon) but an hour drive up into Washington wouldn't be terrible.

I'm assuming the 3rd gen 1500/2500/3500 are interchangeable and all use the 9.25" diff? Actually, I know mine is a light duty rear axle. Are there differences between the LD and HD rear axle?

Actually, per car-part the 3500 offered the Dana 60 in 40.09 instead of Chrysler 9.25" in 3.92. Interesting.

Also, will this mess with my speedo? Edit: speed is measured from the tone ring and sensor on the dif right? If the rear axle isn't spinning any faster, just the drive shaft, then speedo should still work the same?

 

Hmm, I've never thought to check against my parents' van, but I'm reading that the b3500 potentially has larger wheels with more lugs. I'm guessing that means a 3500 rear axle to 1500 swap would mess with my speedo. More than that I guess. Bigger brakes as well it looks like. That would mean I would need the wheels along with the axle assembly, plus probably new tires, plus I would have mismatched front and rear wheels/tires. Not sure I want it stanced like that.

Can you swap the 5 lug hubs for the 8 lug hubs? I have very little experience with this other than spending the weekend adding disc brakes to my trailer which meant new hubs/bearings/seals.

There are plenty of 2500/3500 options within a couple hours of me. I'm looking at 1500 miles for the nearest 1500 option.

 

Speed sensor on 98 and up is on the rear diff, it reads from the carrier, so, gear changes won't effect the speedo.

3500 will likely be an 8 lug rear. Also, springs are wider, so, that won't work, unless you wanna do some SERIOUS modification..... Not to mention the brakes will be a LOT bigger, and throw off your brake balance. (rears will lock up WAY to easy.)

 

Yeah, almost certainly 8 lug 16x7 or whatever instead of 15x7.

The brake thing is interesting. I seem to recall their b3500 being like 600 pounds heavier than my b1500. You're probably right though. I hadn't thought to measure spring width. I did notice that leaf spring packs are aftermarket when I was out there last night poking around. Not that that means anything. I was just surprised.

 

Well the best local trans/gear shop we have estimated $2,500 which just isn't worth it.

However, a guy in a dodge van facebook group says the 3500 axle is a straight swap with no braking problems. Apparently there was an issue with the drive shaft and pinion yoke but I haven't gotten clarification on how that was resolved.

The short of it is that I'm either doing an axle swap or doing the regear myself if I ever get myself a shop with a lift (i'll axle swap on jack stands but I'm not regearing on my back).

 

Yoke on the axle probably wants a larger u-joint, just need to get a hybrid joint that is the correct size for the both the driveshaft, and the yoke.