My intention with mentioning the possible coil spring swap TTB was that most of the parts are readily available out there used.
Custom fab work and cheap are two things that never go well together.
I do not see a D60 as a panacea for all situations, only that just like those TTB parts, they are readily available used and cheap. Plus they are "bolt in" or very close to it. (I do not know where the OP lives but here are a couple of local "to me" examples)
http://denver.craigslist.org/pts/1854452194.html $800 front only
http://denver.craigslist.org/pts/1846190892.html $800 both axles (D60 & 10.25") or $1300 including springs and steering.
http://denver.craigslist.org/pts/1840730314.html $900 front only
http://denver.craigslist.org/pts/1833135506.html $1000 front only
Swapping anything always involves more than you expect in time and $$. But as long as you matched your current 10.25 diff ratio, I think a "shade tree" overhaul is a lot less than $1k for wheel bearings, rotors, pads and ball joints.
I have a 97 F350 Powerstroke CC 4x4 LB with the leaf sprung D60. While it does ride like the 1 ton school bus it is, it is not a buckboard by any means. The RSK and SD springs are in the garage, I am just saving for the Bilsteins, which will bring this OBS up to SD(99-03) ride comfort.
If I had a F250 and was looking to improve on the TTB, I think this is the way to go about it. The parts are reasonable, someone else has already figured it all out (Ford) with the help of some simple bolt on stuff (Sky Off Road) and it is in the skill level of most owners.
fjatheart
- Like we have already mentioned. The D50 leaf sprung TTB is a strong axle, its just designed poorly.
- Deaver and Alcan both make excellent springs but they will not over come this design flaw.
- Quality shocks may help, but the problem is travel, which you guessed it, is limited by the poor design.
Best of luck and keep us posted, Chris