1998 F150 rear axle swap to F250 10.5 Sterling

[Feral Cat Films]

Hi!

I've designed a built a articulating over-landing camper truck but unfortunately I miss calculated the weight and now I have a overloaded F150. The suspension, transmission, brakes have all been upgraded but the 8.8 axle is still there. I really want to swap to a 3/4 ton Sterling F250 axle which I have been told will bolt in and I have a company that will make me custom axles that will fit my 5 lug F150 wheels.

Does anyone have experience with this swap? Will the F150 wheels clear the F250 brakes? Any advice is appreciated!

FYI: I realize the F250 has a different frame, brakes and suspension and that would be ideal but that is just too cost prohibitive at this point. I can not change to a F250 or F350 since the extra $10,000 was and is still too high a price.

 

[UHAULER]

I think Ford made a light duty f250 that same year. I believe it was a 7 lug and had the smaller semi-float sterling rear end. Maybe you could swap rear axle and front end parts.
Or you could put Toyota Tacoma emblems on and call it good.

 

[Feral Cat Films]

Yes, that's where I'm probably pulling the 10.5 axle from. Problem is the F250 SD is a completely different frame then the F150. The body is the same but frame, suspension axles and brakes are different.

I already have a 97 FZJ80 which is the rescue vehicle for the Ford

 

[UHAULER]

Just doing a quick search, it appears the 1998 f250Ld is just a heavy half ton with a semi-floating axle, seven lug wheels,etc. This would probably be the best way to upgrade parts, see what interchanges with your truck. If you decide you still want to put a full-floating 8 lug sterling in then maybe it is possible to convert the front to 8 lug.

https://www.ford-trucks.com/forums/834746-f250-light-duty-with-f150-body.html

 

[pappawheely]

I have no experience with fords of your year but I swapped an 8 lug full floating 14 bolt into my Chevy blazer and just changed the front hubs/rotors to 8 lug to match the rear. Not sure if that's possible on the ford.

 

[Hillbilly Heaven]

If it was me I would just grab a 99-04 sterling from an F350. At most it would need spring pads changed. I know the sterlings will have 3" wide spring pads not certain what width springs you have. You can then re-drill the hubs and disc brake rotor to match your front lug pattern. Since you already said you are overloaded the disc brakes will help some plus it has built in parking brake that can be attached to existing parking brake cable.

 

[Feral Cat Films]

So.......

After 3 days looking at the Ford parts website looks like the Ford Expeditions 9.75 rear axle is the way to go since it has a 3/4 ton axle bearing but still retains the 5 lug wheel.

Basically the Expedition rear axle is a 10.25 semi floater with a 9.75 ring and pinion with rear disk brakes, BUT it goes with the 5 lug wheel. The only issue is the Expedition uses coil springs instead of leaf springs so we have to weld on new $50 leaf spring perches. This seems like the easiest (relative) solution.

 

[Feral Cat Films]

If it was me I would just grab a 99-04 sterling from an F350. At most it would need spring pads changed. I know the sterlings will have 3" wide spring pads not certain what width springs you have. You can then re-drill the hubs and disc brake rotor to match your front lug pattern. Since you already said you are overloaded the disc brakes will help some plus it has built in parking brake that can be attached to existing parking brake cable.

You are right this is a good solution also but the cost of custom axles and drilled rotors would be over $500 + cost of the axle.

 

[Hillbilly Heaven]

No you don't need new axles. Just redrill the rotors and the hubs. Any machine shop can handle this. You will need them to press in new wheel studs for you but total cost around $150

 

[Hillbilly Heaven]

Somewhere on here is a thread about converting the 99-04 sterling from metric bolt pattern to 8x6.5 and using van rotors. Since you will not be using 8 studs then you don't need or want the van rotors. Just redrill the ones on the Sterling.

 

[Hillbilly Heaven]

Sorry I was wrong it was another forum.
https://www.ford-trucks.com/forums/1133951-super-duty-rear-axle-into-a-obs-with-8-on-6-5-a.html

Just follow his lead but using whatever bolt pattern you want.

 

[UHAULER]

So.......

After 3 days looking at the Ford parts website looks like the Ford Expeditions 9.75 rear axle is the way to go since it has a 3/4 ton axle bearing but still retains the 5 lug wheel.

Basically the Expedition rear axle is a 10.25 semi floater with a 9.75 ring and pinion with rear disk brakes, BUT it goes with the 5 lug wheel. The only issue is the Expedition uses coil springs instead of leaf springs so we have to weld on new $50 leaf spring perches. This seems like the easiest (relative) solution.

My 03 f150 supercrew has the sterling semi-float 5 lug.

 

[ExplorerTom]

I know I'm late to the party, but the 9.75 axle from an Expedition of the same gen is the way to go. Plenty strong. And inexpensive.

 

[Ivan]

So.......

After 3 days looking at the Ford parts website looks like the Ford Expeditions 9.75 rear axle is the way to go since it has a 3/4 ton axle bearing but still retains the 5 lug wheel.

Basically the Expedition rear axle is a 10.25 semi floater with a 9.75 ring and pinion with rear disk brakes, BUT it goes with the 5 lug wheel. The only issue is the Expedition uses coil springs instead of leaf springs so we have to weld on new $50 leaf spring perches. This seems like the easiest (relative) solution.

Not entirely true on all counts.

The 9.75 was available in the F150's. Just grab one of those. It's comparable to a Dana 60. It'll be a while before you break it.

ETA: damn this post threw me off on what I actually meant to say: look at the 1999 - 2004 4wd F150's (2004 10th gen is the Heritage edition). Those will have the 9.75 Sterling as an option, especially the Supercrew trucks.

However, look at your door tag and the year of manufacture. I think the late 1996 to 1998 trucks had a slightly different stud size so wheel fitment may or may not be an issue (more than likely not but just fyi). One of the lovable quirks of the 10th gens.

Also, if you haven't done it yet, the Expedition brake swap is a good upgrade over the stock F150 set up.

 

[Feral Cat Films]

We got a used 2001 Ford Expedition 9.75 limited slip rear axle. The original 8.8 is on the floor for comparison.



Used a plasma torch to cut off all the Expedition mounts:



About 20Lbs of steel had to be removed off the Expedition rear end.



RoughStuff spring perch kits lined up ready for welding.