91 Rear End

***runnerrf12*** · 11-04-2009, 10:51 AM

I have a 91 1st gen. I was driving down the interstate and I heard a pop and the brake and anti light came on. It sounded like the there was a roar coming from the rear end. So I tore down the rear end and found a broke a tooth off the pinion. My buddy has a 95 that he has parted out and he still has the rear axle.

So the question is would a 95 rear end fir underneath my 91.

Last edited by runnerrf12 : 11-04-2009 at 01:39 PM. Reason: Adding to it.

Philip · 11-04-2009, 07:17 PM

We need a little more info on your truck. Does the trans have overdrive??

The 95 axle will bolt in. The problem will be on the emg brake cables. There is a difference.

__________________
93 W350 w/duals, fuel pin turned, 6X.018" injectors, 4" exhaust, 3" air intake horn, Super HX40/16, auto, 3:07's axles, 2" skyjacker lift, B&W flatbed

440trk · 11-04-2009, 10:38 PM

Quote:

Originally Posted by Philip

The 95 axle will bolt in.

Really? I would have thought the 94-later rear diff's would be a different width and/or spring perch layout. Good info to know!

__________________
Mike(440trk)

91 W250 LE ~209k miles, 727, 3.07's w/limited slip rear, ALL STOCK

Philip · 11-04-2009, 10:51 PM

The perches are the same. It gets different in the emg brake cables.

__________________
93 W350 w/duals, fuel pin turned, 6X.018" injectors, 4" exhaust, 3" air intake horn, Super HX40/16, auto, 3:07's axles, 2" skyjacker lift, B&W flatbed

***runnerrf12*** · 11-05-2009, 08:22 AM

It is a 5 speed getrag 4x4 what would be the fix for the e-brake cables?

***runnerrf12*** · 11-05-2009, 08:37 AM

Here is a pic

pitman · 11-05-2009, 11:16 AM

Thats a sharp truck

__________________
93 3/4 ton 5_speed CUMMINS. Star wheel all the way down. Smoke screw tightened.Denny t fuel pin. 100 horse injectors Proud Contributor to Global Warming!!!!!

Philip · 11-05-2009, 08:04 PM

runnerr I can't say for sure what the difference is in the eng brake cables. They did some changes. I don't have complete details what the issue was.

__________________
93 W350 w/duals, fuel pin turned, 6X.018" injectors, 4" exhaust, 3" air intake horn, Super HX40/16, auto, 3:07's axles, 2" skyjacker lift, B&W flatbed

Kody_a · 11-05-2009, 08:21 PM

Hi there,

I have a wrecked 97 2500 cummins with a 4.10 axle sittin out front. I can prolly take some pictures of the emg brake cables if you want. Just let me know,

Kody

***runnerrf12*** · 11-06-2009, 01:55 PM

No thanks for the pictures. Thanks though.

I am going to go get my truck this evening and we are going to look at it to see if it works. The plan is to switch them out this evening. I have been doing some research on the internet and I found some one that has done the same kind of swap (with a 2nd gen axle). I will let you guys know how it goes. Thanks for all your guys help.

1stgen3rdgendodge · 11-06-2009, 07:55 PM

good info to know. id be slapping an 80 underneath the rear.

__________________
93 W250 4x4 125k auto hx40 recon smoked cab lights lots of body work injectors coming soon

01 2500 4x4 auto 2" leveling kit tail lights silencer ring MIA Edge Juice with Attitude custom 4" into dual 6" stacks AEM gauges

***runnerrf12*** · 11-11-2009, 04:05 PM

Well for all you guys that want to know a 95 2500 dana 80 will work. But in order for it to work there is a little bit of work to get it to work. The first thing we ran into was the shock mounts on the 1st gens vs the 2nd gens. We had to grind off the shock mounts off of the axle, cause you will not need them on the axle tubing since they mount to the bottom u bolt plates. Secondly we had to bore the holes out on the u bolt plates in order to get the u bolts to line up right. We also had to grind down the spring perches from 3" to 2.5", we put a thin piece of plate on each perch (we done this cause the perch has two holes in the top and we thought that the block would wobble back and forth in it). We got everything to bolt up after that. The next problem we ran into was hooking up the emergency brake cable. We made the cable into a eye from the one from the rear and the same on the front. Hooked them together with a shackle. The last thing we had to do was take and have the drive shaft shortened by 3".

____________
91' w250 4x4, 283K, 5 speed, stock engine, & rolling dana 80 3.54's in rear

11-04-2009, 10:51 AM	#1 (permalink)
*runnerrf12* Newbie Join Date: Sep 2009 Posts: 10 Thanks: 0 Thanked 0 Times in 0 Posts runnerrf12's Truck Pics	91 Rear End I have a 91 1st gen. I was driving down the interstate and I heard a pop and the brake and anti light came on. It sounded like the there was a roar coming from the rear end. So I tore down the rear end and found a broke a tooth off the pinion. My buddy has a 95 that he has parted out and he still has the rear axle. So the question is would a 95 rear end fir underneath my 91. Last edited by runnerrf12 : 11-04-2009 at 01:39 PM. Reason: Adding to it.

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11-04-2009, 07:17 PM	#2 (permalink)
Philip 1ST GEN MODERATOR Join Date: Nov 2007 Location: Indiana Posts: 5,115 Thanks: 2 Thanked 131 Times in 121 Posts Philip's Truck Pics	We need a little more info on your truck. Does the trans have overdrive?? The 95 axle will bolt in. The problem will be on the emg brake cables. There is a difference. __________________ 93 W350 w/duals, fuel pin turned, 6X.018" injectors, 4" exhaust, 3" air intake horn, Super HX40/16, auto, 3:07's axles, 2" skyjacker lift, B&W flatbed

11-04-2009, 10:51 PM	#4 (permalink)
Philip 1ST GEN MODERATOR Join Date: Nov 2007 Location: Indiana Posts: 5,115 Thanks: 2 Thanked 131 Times in 121 Posts Philip's Truck Pics	The perches are the same. It gets different in the emg brake cables. __________________ 93 W350 w/duals, fuel pin turned, 6X.018" injectors, 4" exhaust, 3" air intake horn, Super HX40/16, auto, 3:07's axles, 2" skyjacker lift, B&W flatbed

11-05-2009, 08:22 AM	#5 (permalink)
*runnerrf12* Newbie Join Date: Sep 2009 Posts: 10 Thanks: 0 Thanked 0 Times in 0 Posts runnerrf12's Truck Pics	It is a 5 speed getrag 4x4 what would be the fix for the e-brake cables?

11-05-2009, 08:37 AM	#6 (permalink)
*runnerrf12* Newbie Join Date: Sep 2009 Posts: 10 Thanks: 0 Thanked 0 Times in 0 Posts runnerrf12's Truck Pics	Here is a pic

11-05-2009, 11:16 AM	#7 (permalink)
pitman Cummins Fan Join Date: May 2009 Location: Rolla missouri Posts: 83 Thanks: 6 Thanked 1 Time in 1 Post pitman's Truck Pics	Thats a sharp truck __________________ 93 3/4 ton 5_speed CUMMINS. Star wheel all the way down. Smoke screw tightened.Denny t fuel pin. 100 horse injectors Proud Contributor to Global Warming!!!!!

11-05-2009, 08:04 PM	#8 (permalink)
Philip 1ST GEN MODERATOR Join Date: Nov 2007 Location: Indiana Posts: 5,115 Thanks: 2 Thanked 131 Times in 121 Posts Philip's Truck Pics	runnerr I can't say for sure what the difference is in the eng brake cables. They did some changes. I don't have complete details what the issue was. __________________ 93 W350 w/duals, fuel pin turned, 6X.018" injectors, 4" exhaust, 3" air intake horn, Super HX40/16, auto, 3:07's axles, 2" skyjacker lift, B&W flatbed

11-05-2009, 08:21 PM	#9 (permalink)
Kody_a Newbie Join Date: Sep 2009 Location: Cresco,pa Posts: 4 Thanks: 0 Thanked 0 Times in 0 Posts Kody_a's Truck Pics	Hi there, I have a wrecked 97 2500 cummins with a 4.10 axle sittin out front. I can prolly take some pictures of the emg brake cables if you want. Just let me know, Kody

11-06-2009, 01:55 PM	#10 (permalink)
*runnerrf12* Newbie Join Date: Sep 2009 Posts: 10 Thanks: 0 Thanked 0 Times in 0 Posts runnerrf12's Truck Pics	No thanks for the pictures. Thanks though. I am going to go get my truck this evening and we are going to look at it to see if it works. The plan is to switch them out this evening. I have been doing some research on the internet and I found some one that has done the same kind of swap (with a 2nd gen axle). I will let you guys know how it goes. Thanks for all your guys help.

11-06-2009, 07:55 PM	#11 (permalink)
1stgen3rdgendodge Cummins Nut Join Date: Jun 2009 Location: Mount Union, PA Posts: 324 Thanks: 5 Thanked 5 Times in 5 Posts 1stgen3rdgendodge's Truck Pics	good info to know. id be slapping an 80 underneath the rear. __________________ 93 W250 4x4 125k auto hx40 recon smoked cab lights lots of body work injectors coming soon 01 2500 4x4 auto 2" leveling kit tail lights silencer ring MIA Edge Juice with Attitude custom 4" into dual 6" stacks AEM gauges

11-11-2009, 04:05 PM	#12 (permalink)
*runnerrf12* Newbie Join Date: Sep 2009 Posts: 10 Thanks: 0 Thanked 0 Times in 0 Posts runnerrf12's Truck Pics	Well for all you guys that want to know a 95 2500 dana 80 will work. But in order for it to work there is a little bit of work to get it to work. The first thing we ran into was the shock mounts on the 1st gens vs the 2nd gens. We had to grind off the shock mounts off of the axle, cause you will not need them on the axle tubing since they mount to the bottom u bolt plates. Secondly we had to bore the holes out on the u bolt plates in order to get the u bolts to line up right. We also had to grind down the spring perches from 3" to 2.5", we put a thin piece of plate on each perch (we done this cause the perch has two holes in the top and we thought that the block would wobble back and forth in it). We got everything to bolt up after that. The next problem we ran into was hooking up the emergency brake cable. We made the cable into a eye from the one from the rear and the same on the front. Hooked them together with a shackle. The last thing we had to do was take and have the drive shaft shortened by 3". ____________ 91' w250 4x4, 283K, 5 speed, stock engine, & rolling dana 80 3.54's in rear