97 manual locking hub conversion.

[jagert59]

Originally Posted by Fo.rrest

if i do not have that end mill at the school are these the ones i will need? OSG 4.4MM X 13MM CARBIDE END MILLS(5) - NEW on eBay.ca (item 200401768608 end time 10-Nov-09 14:54:14 EST)

Nope, that's a 4.4mm cutting dia mill, after doing a little checking online I'm not sure they even make a 13mm end mill, looks like either 12mm or 14mm. I used 1/2"-20 bolts which are 12.7mm dia. I suppose you could use the 14mm end mill that's the size of the holes in the knuckle, just leaves alot of slop if you use 1/2" bolts. If you have access to a CNC mill you can program the mill to cut the holes any diameter you want, which is the method I used.

The hole layout of the Dodge knuckles is a 140mm(5.512") bolt circle with 4 evenly spaced holes, the Ford splindle has 5 holes that are NOT evenly spaced on a 5.25" bolt circle.

Tom

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98 Club Cab 12v 4x4 Sport Auto BHAF, Ford Hub Swap

[Fo.rrest]

okay so we dont have a 13 mm die but i found a shop intown with a cnc mill. would you be able to do me a huge favor and draw picture explaing with i gotta get done cause i got all the ford dana 60 parts and im wanting to do this sometime this weekend. and will i still be useing the dodge balljoints or ford ball joints?

[HEEPJEEP]

I don't understand... Why not use the Ford Knuckles and calipers...

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'97 4x4, 12 v, SC/LB work truck/DD probably a bad P7100 pump... Goerend VB and triple disc, Suncoast rebuild, Billet in/out, billet flex plate, 62/65/13ss +S475, Weston's 5x.014's

[jagert59]

You'll leave the ball joints alone along with the knuckles. do a search on here for posts on how to change your front unit bearings. This will give you the information on how to take apart the stock Dodge unit bearings. Once you have the unit bearing removed you will need to seperate the outer an inner axle shafts at the u-joint, if your u-joints are in good shape you can reuse them, I chose to replace mine. Put the Ford outer stub shafts together with the Dodge inner axle shafts and put the assemblies back in the axle.

Install the modified Ford spindles on the Dodge knuckles, it's best if you line up the holes by installing bolts from the outside in the 4 holes that you had milled in the spindles, I had to "persuade" mine to go together. You should brush some anti sieze onto the spindle where it mates to the knuckle to make it easier to install and remove later. After you have the splindle completely seated in the knuckle remove the bolts that you used to line it up and insert the from the inside of the knuckle back through the holes( I used socket head cap screws 1/2-20 x 1.5" the SHCS is better than a hex head as theres not much room for a hex head inside the knuckle). Put the nuts on the bolts and tighten them.

Now you are ready to install the hubs on the spindles

Tom

__________________
98 Club Cab 12v 4x4 Sport Auto BHAF, Ford Hub Swap

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Last edited by jagert59 : 11-04-2009 at 08:55 PM.

[Fo.rrest]

okay so i still dont quiet understand what im drilling out to fit what. what part# on the photo?

[jagert59]

Originally Posted by Fo.rrest

okay so i still dont quiet understand what im drilling out to fit what. what part# on the photo?

Part 61 on the diagram is the spindle, looks like this...



Part 66 on the diagram is the hub

__________________
98 Club Cab 12v 4x4 Sport Auto BHAF, Ford Hub Swap

[Fo.rrest]

ohhh okay. so i really could just use a 13mm carbide drill bit on the mill to make theos holes correct?

[HEEPJEEP]

Jager. The ID of the stock Ford knuckle and the stock Dodge knuckle were the same? Or the raised portion on the back of the Ford spindle was smaller diameter? That tight fit is to help relieve the forces off the spindle to knuckle bolts.

With the c-clip on the axle shaft, the ujoint looks to be in the correct position (centered between the centers of the two BJ's)??? If it isn't, when turned it's going to get interesting eventually.

__________________
'97 4x4, 12 v, SC/LB work truck/DD probably a bad P7100 pump... Goerend VB and triple disc, Suncoast rebuild, Billet in/out, billet flex plate, 62/65/13ss +S475, Weston's 5x.014's

[jagert59]

Originally Posted by Fo.rrest

okay so i still dont quiet understand what im drilling out to fit what. what part# on the photo?

Here is a link to the install instructions for the EMS kit...

http://emsoffroad.com/EMS_New/Tech_M...20DOD%20SD.pdf

__________________
98 Club Cab 12v 4x4 Sport Auto BHAF, Ford Hub Swap

[jagert59]

Originally Posted by HEEPJEEP

Jager. The ID of the stock Ford knuckle and the stock Dodge knuckle were the same? Or the raised portion on the back of the Ford spindle was smaller diameter? That tight fit is to help relieve the forces off the spindle to knuckle bolts.

The hole in the Dodge knuckle is the same size as the hole in the Ford knuckle. The EMS kit uses a stock Ford spindle that has been modified with the Dodge hole pattern

With the c-clip on the axle shaft, the ujoint looks to be in the correct position (centered between the centers of the two BJ's)??? If it isn't, when turned it's going to get interesting eventually.

I am not running a c-clip on the outer stub shaft, the axle I took my parts off of did not have the c-clip, I never ran a c-clip on my Jeep with a Frod Dana 60 front axle and never had any issuses. As stated earlier in this thread I'm just copying what EMS is doing only I'm using used parts rather than new. I even got the rotor information from EMS.

Tom

__________________
98 Club Cab 12v 4x4 Sport Auto BHAF, Ford Hub Swap

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Last edited by jagert59 : 11-05-2009 at 12:37 AM.

[HEEPJEEP]

Originally Posted by jagert59

I am not running a c-clip on the outer stub shaft, the axle I took my parts off of did not have the c-clip, I never ran a c-clip on my Jeep with a Frod Dana 60 front axle and never had any issuses. As stated earlier in this thread I'm just copying what EMS is doing only I'm using used parts rather than new. I even got the rotor information from EMS.

Tom

Assuming you meant Ford spindle, not knuckle.

Without the c-clip on the stub shaft it doesn't hold the seal properly against the back of the spindle. This can allow contaminants into the spindle.

I also am using all used parts. Fo.rrest said he got the parts from a 1998 Ford F350. He can save a lot of time and money and go back and just swap those knuckles/calipers on (Ford and Dodge use the same BJ's), and just have to deal with simple steering mods. I would pull the Ford steering and make that work honestly. Something a grinder and welder can fix easily instead of machine work. And, he can still go back to stock.

__________________
'97 4x4, 12 v, SC/LB work truck/DD probably a bad P7100 pump... Goerend VB and triple disc, Suncoast rebuild, Billet in/out, billet flex plate, 62/65/13ss +S475, Weston's 5x.014's

[98snowman]

if you have the heavy front axle you most likely have a dana 80 out back