94-99 front brake upgrades.......what are my options?

[Albino99]

Hello! I own a 1999 2500 with the single piston calipers up front. I dislike the design of how the rotors are pressed on from the back with the wheel studs. I will need to replace my brakes soon and want to know if anyone sells a worthwhile upgrade for the fronts? I've heard people swapping to 3rd gen rotors & dual piston calipers........... but that only works on 01-02 Rams. I need something that is designed for 94-99 pickups with the single piston setup. I've also heard that EGR makes a drilled/slotted rotor for these trucks, but many say it didn't make any difference compared to stock and worn out at the same rate. I have also looked at doing a manual hub conversion and wondering if the rotors mount by "slip-on" with the wheel studs? I just don't have the labor time & money to track down a used 01-02 front axle and do a swap. I love my 99, but feel my front brake options are extremely limited. Any one find a good solution or an upgrade that works? My bottom line is serviceability & better braking performance.

 

[Stox5225]

For a legit upgrade, I believe the Ford D60 manual hub conversion seems to be the way to go. A few people on CF have done the swap that I know of. If you can find an axle, it’s not that bad cost wise. It’s certainly in my future as I don’t spend much time in 4x4. With some research, you can find those answers.

 

[Albino99]

For a legit upgrade, I believe the Ford D60 manual hub conversion seems to be the way to go. A few people on CF have done the swap that I know of. If you can find an axle, it’s not that bad cost wise. It’s certainly in my future as I don’t spend much time in 4x4. With some research, you can find those answers.

I am aware of the Ford D60 upgrade. I have spent hours cruising the internet and reading many 4x4 forums on how they are doing them. The downside is that these axles/parts are very popular for 4x4 (off road jeep builders) and not easily found at wrecking yards or Craigslist. Most wrecking companies near where I live have closed down due to tight EPA regulations and tough local permitting costs. It would be nice to find a wrecked rig or someone who has these parts collected and decided to go another route.

 

[JR]

Unfortunately the Ford parts are the only option if you want to get away from the pressed on rotors.

 

[Albino99]

Unfortunately the Ford parts are the only option if you want to get away from the pressed on rotors.

I am curious if the aftermarket locking hubs (yukon gear, spyntec, dynatrac, etc) use the Ford Dana 60 design for slipping the brake rotors on?

 

[JR]

Factory brakes are retained.

I am curious if the aftermarket locking hubs (yukon gear, spyntec, dynatrac, etc) use the Ford Dana 60 design for slipping the brake rotors on?

 

[Albino99]

Factory brakes are retained.

I guess my quest continues for finding Ford D60 hubs.

 

[Albino99]

Did some further reading and found that Ford F350 SRW trucks equipped with Dana 60's up front come with dual piston calipers. These calipers seem like a nice upgrade for sure. I found several 92-97 complete Dana 60's on Ebay for around $800-$1000. Most all of them are local pickup only. Perhaps some of larger wrecking yards throughout my state have something in their inventory? Just need a 92-97 F350 Dana 60 Front.

 

[Albino99]

I actually found a local guy who was selling a complete 1997 F350 Dana 60 front axle complete (wheel to wheel). I contacted him and made arrangements to come get it. Hoping it all works out.

 

[Stox5225]

How much? I want to know how much I should start saving lol.

 

[Albino99]

How much? I want to know how much I should start saving lol.

Well, it was a complete success! I was able to score a 1997 F350 SRW Dana 60! The guy I bought it from knew a lot about these axles and the TTB50's. He was very aware of the Dodge conversion that people like to do with these axles. I guess I was the first person to actually show up with cash and not BS him. Everything is all there for the conversion. I guess all I need to do is machine the hub down slightly to 4.77" (according to other's online who are running stock Dodge wheels and 3rd gen wheels). I'm pretty excited for this conversion and look forward to better braking with the twin piston Ford calipers. We ended up settling @ $800. on the complete axle. I hope to gain back a little bit of cash by selling the axle housing/gears.

 

[gtwitch]

Does anyone know if a swap is possible using the complete front axle from a 2001-2002 2500 into a 98.5-99??
gtwitch in wyoming

 

[JMcCoy]

I have the Ford hub conversion. You will absolutely love it. Best thing i ever did. Stips straight every time. I did a write up on it with photos here in the TDR several years ago.

 

[Regcabguy]

Dodge could have just added a caliper piston in '94 and greatly enhanced the braking.
The cost would have been minimal. My BIL's F-250 of the same period stops so much better than my 24v ever did. Glad there's a solution.

 

[Albino99]

I have the Ford hub conversion. You will absolutely love it. Best thing i ever did. Stips straight every time. I did a write up on it with photos here in the TDR several years ago.

Good to know someone else on the board has tried this conversion with good success. I am very excited to install the Ford hubs. The next thing I need to do is have the outer hub diameter slightly machined down to 4.77" so that I can continue to run my polished aluminum 3rd gen ram wheels. I will also need to cut out the center hubcap to allow the locking hub to protrude through.

 

[Albino99]

I have the Ford hub conversion. You will absolutely love it. Best thing i ever did. Stips straight every time. I did a write up on it with photos here in the TDR several years ago.

I just looked up your old thread.............great write-up! The Timken part #'s were also a big help. For anyone else who wants to read a good article on this: https://www.turbodieselregister.com/threads/whoa-nellie.226856/

 

[JMcCoy]

Just checking in to see how the project is coming along.

 

[Albino99]

Just checking in to see how the project is coming along.

I have not done the physical swap yet, but I have disassembled the hubs/knuckles off the Ford Dana 60. I will need to clean the grease from the parts and change out the old bearings/seals for new ones.

 

[JMcCoy]

Sounds good. Might want to consider changing your inner axle seals while you have it all apart. Hope it all goes well.