9.25ZF to AAM10.5 HD rear axle swap on 2014 RAM 1500

[Pmexpert]

So...after changing my rear gears three times within 40000miles, I've decided to find a better solution rather than changing gears so often.


What do we have? 2014 RAM 1500, 5.7L, custom tune for 91 octane, 37" tires, 4.56 gears... As for the gears: those were made by Yukon Gears, break-in done perfectly every time, so no issues here. After break-in, 60-70% throttle and first noise appears. All works were done in a different workshops(including official dealer), but result was the same - noisy sounds all the way. Those wasn't really loud, but annoying.

As far as I swapped gears to 4.56 in the past, I was searching for the rear axle with 4.56 gears. The best one that matches my application is AAM 10.5 full floating HD axle with e-locker that was installed on 2009-2013 RAM 2500 Power Wagon. It wasn't easy to get a new axle as it was already discontinued since last year. But I got it!(God bless Arizona)

There wasn't an issue to weld 1500 axle brackets to HD axle


The biggest problem is ABS - as AAM10.5 has only one speed sensor above the gear, so ABS tone rings needed (made by Yukon) that fits 2014 RAM 1500. Those need to be put on the hub and adjusted well.

Drill a hole for the sensor



Then a bracket for the sensor need to be welded to keep it in place.


I've decided to install new shocks 2.5 FOX with reservoirs to improve handling of rear axle that is significally heavier.


Oh, I had a rear sway bar made by Hellwig for the 2500(bought in the past by mistake), that fits HD axle perfectly!



The last thing need to be done is a driveshaft. Hopefully it will be ready tomorrow, so will ran a first test...

 

[Pmexpert]

By the way, idea is not unique as it seems) As seen some spy photos of the upcoming TRX, FCA also used HD axle(8 lugs) for the rear

 

[RLJ10X]

Wow! That was a ton of work. Looks expensive, as well. You must REALLY like your truck! That took a little bit of imagination and a lot of ingenuity. Well done.

 

[Pmexpert]

Wow! That was a ton of work. Looks expensive, as well. You must REALLY like your truck! That took a little bit of imagination and a lot of ingenuity. Well done.

Thanks bud! Yes, it started as a funny idea but in the end this could be a best solution for those with the similar problems. Today a brand new driveshaft arrived, so hopefully will ride this babe ssonest )

 

[6.7CumminsDrvr]

Been a dream of mine to throw the “old” 4.56 PW axles under my ‘14.........but i’d Like to SAS the front too!

 

[Pmexpert]

Been a dream of mine to throw the “old” 4.56 PW axles under my ‘14.........but i’d Like to SAS the front too!

SAS in the front is possible also but in my case there is no reason for that. I'm not into rock crawling. But I'm thinking of 4444 to 4445 swap and 5.7 to 6.4

 

[QwikKota]

So the front is still regular 5 bolt hub, correct? How did you get the wheels to match up?

 

[Pmexpert]

So the front is still regular 5 bolt hub, correct? How did you get the wheels to match up?

Yes, the front remains with 5 bolt hub. I bought the same wheels(brand, design and offset) but 8 8x65 bolt pattern. So having 2 Fuel Vapor and 2 KMC XD wheels now without any chance to
sell those)


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[QwikKota]

Yes, the front remains with 5 bolt hub. I bought the same wheels(brand, design and offset) but 8 8x65 bolt pattern. So having 2 Fuel Vapor and 2 KMC XD wheels now without any chance to
sell those)


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Sounds expensive. Post a pic I am still confused.

 

[Pmexpert]

Sounds expensive. Post a pic I am still confused.

Sure! I have winter and Summer sets
So 2 of each design

For 8 lugs hub


So the rear hubs looks like this





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[QwikKota]

Ah, that makes more sense now. 2 complete sets.

 

[6.7CumminsDrvr]

SAS in the front is possible also but in my case there is no reason for that. I'm not into rock crawling. But I'm thinking of 4444 to 4445 swap and 5.7 to 6.4

You and I think ALOT alike. 44 to 45 swap is already on the “to-do” list. If I could get 4:56’s for my front end I’d do the same as you and call it a day but I don’t want to swap in a smaller low pinion front diff into my truck to get 4:56’s.

Figured I’d just be patient and do the swap one day if the boss lady dosen’t sign off on a PW.

 

[Pmexpert]

You and I think ALOT alike. 44 to 45 swap is already on the “to-do” list. If I could get 4:56’s for my front end I’d do the same as you and call it a day but I don’t want to swap in a smaller low pinion front diff into my truck to get 4:56’s.

Figured I’d just be patient and do the swap one day if the boss lady dosen’t sign off on a PW.

My front end is 2012 RAM1500(8” corporate) with 4.56 G2 gears. Another option for the front I keep in mind is IFS from Dynatrac. That’s a tough one.



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[Pmexpert]

Finally, custom driveshaft arrived and installed


Everything runs smoothly, waiting for 500-600 miles to oil change and after will start a real test)



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[6.7CumminsDrvr]

My front end is 2012 RAM1500(8” corporate) with 4.56 G2 gears. Another option for the front I keep in mind is IFS from Dynatrac. That’s a tough one.



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Heck, I looked at that Dynatrac IFS too......was trying to figure out of the axle disconnect would be able to mount up to that or if I’d have to bite the bullet on a one off custome passenger CV? Then the CV would be rather long, not sure if that would be an issue. And after all that it gets back to cost and would I be better off doing the SAS?!

Be so simple if you could swap gears on the ZF front end.

I need a cheaper hobby

 

[Pmexpert]

Heck, I looked at that Dynatrac IFS too......was trying to figure out of the axle disconnect would be able to mount up to that or if I’d have to bite the bullet on a one off custome passenger CV? Then the CV would be rather long, not sure if that would be an issue. And after all that it gets back to cost and would I be better off doing the SAS?!

Be so simple if you could swap gears on the ZF front end.

I need a cheaper hobby

Yes, you’ll need custom CV and you shouldn’t be worried about length as those CVs are almost 1 1/2 thick
Doing the SAS wouldn’t be much cheaper, as you’ll need to buy a complete front end of the 2500. Then to adapt everything(all brackets, crossmembers etc) on your frame and body so SAS can fit there.
So there is no cheaper hobby, rather than bottle caps collection)


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[RLJ10X]

A lot of guys go cheap on lifts, and end up really screwing thing up. Looks like PM went first class all the way. Very cool. Suspensions, wether they're on a sport bike, car, or truck have always been a mystery to me. I have to pay someone who knows what they're doing.

 

[Pmexpert]

A lot of guys go cheap on lifts, and end up really screwing thing up. Looks like PM went first class all the way. Very cool. Suspensions, wether they're on a sport bike, car, or truck have always been a mystery to me. I have to pay someone who knows what they're doing.

I’ve found a great replacement for the OEM rear control arms. Something really cool and heavy duty stuff from Core4x4! That’s the last thing I need to install with a new rear end


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