2003 Ram 1500 SAS

CowboyKyle · May 22, 2010

This will be a condensed version of the threads I have on several other sites. If you have any specific questions, or need/want specific pics, please do not hesitate to ask.

It all started with a howling rear end, and a front diff that looked like this when I pulled the cover off.

I picked up a set of 2003 F-350 axles locally: a D60 front and a Sterling 10.5" rear. I was also lucky enough to get the drive shafts.

I then notched and massaged the driver side perch for a bracket I made. This would allow me to link it, with out having to weld to the cast.

CowboyKyle · May 22, 2010

My attention then turned towards the rear. I got the Sterling hung with very little fuss. I was able to hook up the e-brake just like it came off my 9.25" factory rear. I also hooked up the brake lines with the use of 2 adapters and a 12" hose.

CowboyKyle · May 22, 2010

Once I took it for a test drive on the IFS and the Sterling rear, I was satisfied. I then started working on the front axle. Here are a few pics of the U-bolted bracket I built.

Then it was time to tear out the IFS. I built a frame stand to roll the truck around. It has come inn VERY handy.

Once I did that, it was on to designing the placement of the front suspension components. To do this, I first needed to figure out my center of gravity. That was crucial information I had to plug into the 3-link calculator.

CowboyKyle · May 22, 2010

After I had the numbers, I started using the the blue tip wrench.

I then built a cross member to replace the lower control arm (LCA) cross member that needed to come out.

CowboyKyle · May 22, 2010

I then ordered a few joints so I could start build brackets and tabs for them to mount to. That also included a truss for a 1979 D60 that I massaged to fit the 2003 D60.

I would eventually turn this pile of steel into a cross member.

CowboyKyle · May 22, 2010

Then I needed to weld on tabs. To get the proper angle, I had to plot out my link geometry on the concrete floor.

CowboyKyle · May 22, 2010

This brings us to my latest update. This is what you call getting very lucky. It still may not work yet, but after cutting 1.5" off my output shaft (2" still showing), it's looking very promising. 1410 on both sides of the bearing and 1350 at the axle. As you can see, I plan on spacing up the bearing. It's a bastardized combination of the front and rear stock Ford shafts.

YouTube - video-2010-05-19-20-33-18

Horns · May 23, 2010

Nice build. Can't wait to see her when she's done.

woodruff112 · May 23, 2010

so your converting your axles to dana 60s.. dang thats ona half ton?!? man thats a tough challange..

CowboyKyle · May 23, 2010

woodruff112 said:
so your converting your axles to dana 60s.. dang thats ona half ton?!? man thats a tough challange..

Well the front is a D60. The rear is a Ford Sterling 10.5". Basically the Ford equivalent of a 14 bolt full floater. And yes... it has been a lot of work so far.

SMKN · Jun 27, 2010

Any finished pics of this build???

RubberFrog · Jun 27, 2010

I've been living vicariously thru this build for a while now.

ramhunter9 · Jun 27, 2010

wow nice build man .

CowboyKyle · Jun 27, 2010

SMKNRAM said:
Any finished pics of this build???

I wish.

RubberFrog said:
I've been living vicariously thru this build for a while now.

ramhunter9 said:
wow nice build man .

Thanks.

I just got these in last week ($1,200) and more parts are on their way.

ramhunter9 · Jun 27, 2010

that thing is going to be a beast ....

matt99 · Jun 27, 2010

damn man, you are a master of metal haha....it will be a beast

AParrette · Jun 30, 2010

hella nice ass build

CowboyKyle · Jun 30, 2010

I gots me some goodies from the chocolate Santa!

cwboyjohnny24 · Jun 30, 2010

I can't wait to see the finished project man!!!!!

ramhunter9 · Jun 30, 2010

holly crap .... that thing is going to be solid as a tank when your done

2003 Ram 1500 SAS

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