2nd Gen Non-Engine/Transmission 1996 Front End Rebuild

[12Vmudder]

Hey Guys,

This is my first post I think since I just joined a month or two ago... love reading the site trying to keep up with everything on my truck that was new to me in October. The guy I bought the truck from said the only thing he had done to the front end was replace the track bar and the truck now has 240,000 on it. I'm going to drive to New Orleans this summer to do an internship and want to redo the front end before I go.

I crawled under it yesterday to check it out and from what I could tell... its all worn pretty good... I know for a fact my steering box is leaking so probably worn out. . and my driver side wheel u-joint is clicking.

My plan is to keep this truck forever to use as a toy and hopefully build into a pulling truck so if I'm going to rebuild the front end its going to be with reliable, heavy duty parts.

Here is my initial take on what I need and would like input for what parts to use, where to get them, and other things I left out that you would do if doing this. .

Ok here it goes

Wheel U-Joints - both sides -
Ball Joints - both sides upper and lower - MOOG
Tie Rods - all four pieces - MOOG
Steering Gear Box - 3 turn - maybe PSC
Sway Bar Connectors - both - MOOG
DSS - Where to buy??
Upgrade to 3rd Gen Track Bar - ??
or do Luke's Links?
Polyurethane Control arm Bushings - Energy Suspensions
Rotors - something good?
Brake Pads - something good?
Calipers - dont know if I need them but what would you recommend?
Bilstein 5100 shocks all 4 corners
Coil Spacer or Longer Coils to level truck?
I think my wheel hubs should be alright shouldn't they?

Sorry for all the questions but this is looking like its going to be a pretty big project and a pricey one at that. . my best estimate so far is 1500 - 2000 in parts.

Thanks in advance for all the help,
12Vmudder

 

[Dave M]

I've been through a few parts chasing death wobble and finally fixed it a few months ago. I have my reasons for picking the parts I used but I'll just list them.



Definately get 3rd Gen Track bar (Solid Steel) and 3rd Gen TB bracket (PSC or Sourceatomotive. biz).



PSC 3 turn box SG-841M. DSS from PSC or Sourceautomotive.



Poly Control Arm bushings Energy Suspension from summittracing.com I used Bilsteins (Yellow/Blue) but I believe the 5100's are better (not sure).



Steering Stabilizers from Summitracing or your choice.



New Moog Pitman arm



New Hydroboost unit from Hydratechbracking.



New drilled/slotted Rotors NAPA The NAPA drilled/slotted rotors were directional (Left/right) and I mixed them up and had to remove both again. . be carefull. The NAPA rotors were PN for Right PR86324R and PN for Left PR86324L my cost (with discount) were $134 apiece. These rotors had much less slots and holes than the Power Slot so I feel they are strong enough and won't warp.



The NAPA Super Duty pads were SD-7339M I believe and $70. Very nice pads with beveled ends on pad surface.



Enery Suspension Sway Bar greasable bushings.



Energy Suspension End Link Bushings and Moog end links.



I might mention that if I were replacing a large number oF tie rods then (if it was me) I would convert from inverted T to Y steering which would add about $400. See this thread https://www.turbodieselregister.com...ions/197276-steering-inverted-y-change-t.html

Good Luck,

Dave

 

[12Vmudder]

By comparing the parts on Orielly's website, I would need MOOG part numbers ES3248RT, DS1308T, DS1309, and ES3249RT which total 387. 96 for the stock "Y" setup.

Or if I understand this correctly I could get the following part numbers listed for a 1999 3500 and it would be a direct swap? Part numbers ES3496, ES3497, DS1456, and DS1459 which total 363. 96 for the "T" setup

So if I'm understanding this right I could upgrade to a newer design that is better and cheaper? Please let me know if this is correct information

Thanks,
12Vmudder

 

[charlessmith]

When you pull the axles to replace the front outside U joints, you will probably find grease on the axles, meaning you need to replace the inner grease seals. Pull the differential and you can get at them while the axles are out.

If you are looking for really stiff shocks to control washboard road bouncing, I found that the only thing that works well are the Rancho 9000RS shocks.

 

[Dave M]

Thuren makes a cross-over steering setup to consider also:



Thuren Fabrication- Crossover steering kits



I've not decided which way to go yet.

 

[12Vmudder]

I'm getting closer to being ready to start ordering parts... So far Im pretty sure I'm getting the PSC 841M steering box, and the sourceautomotive solid steel steering package 2 which comes with the DSS, track bar conversion bracket, and an adjuctable track bar,



I'm kinda liking the thuren crossover steering as it looks simple and very strong. . Anyone running this kit that can give some feedback?



I'm also considering the skyjacker D25 coil springs that give 2. 5" of lift along with some bilstein 5100's. . Should this combination be ok with everything else I'm doing? Anyone know of good place to get this stuff? right now I'm looking at www.jackit.com. . $181 for the coils and $80 x 4 for the shocks



I'm probably going to get all my moog ball joints and other things I need like wheel joints at rockauto.com



Now I need to figure out what I'm going to do about my brake setup...

 

[Davcruz]

You can check Summit Racing for SkyJacker parts also. Additionally topguncustoms.com .

Unless you are a heavy off roader I would not recommend any steering setup that uses heim joints. My reasons are this: 1) they wear out fast during DD and are expensive to replace 2) some alignment shops will not perform alignments on a truck with heim joints 3) the factory Dodge 1 ton "T" setup is very strong and replacement parts can be found at most auto parts stores

 

[12Vmudder]

Ya, I'm not a heavy off-roader and was kinda wondering about that. . So I should get all the tie rod componets for a 99 3500 in order to do the T setup right? I have already priced out all of the parts for a 99 3500 MOOG and it cheaper than redoing the setup I have now

 

[Davcruz]

98-99 1 ton HD steering, yep. I have gotten my parts from rockauto.com and I always get the Moog line.

FYI, if your draglink TRE is not worn you do not need to get the 1 ton unit, that is the same part on both setups.

 

[12Vmudder]

Ok I'm getting the 99 T steering setup and now my next question is. . I'm thinking about getting a dual steering stabilizer kit from top gun customz but do I need to get one for 94-97 or do I need the one for 98-02? They look completely different

 

[12Vmudder]

I'm looking at getting the Energy Suspension control arm bushing kit and was also thinking about getting the greaseable sway bar bushings but they offer them for a 30mm sway bar and a 32mm sway bar. . any easy way to tell which one I have?

 

[Dave M]

I'm looking at getting the Energy Suspension control arm bushing kit and was also thinking about getting the greaseable sway bar bushings but they offer them for a 30mm sway bar and a 32mm sway bar. . any easy way to tell which one I have?

I don't know an easy way. I just got my calipers and took a few measurements. I don't remember which ones I finally got.

 

[hilda]

rockauto.com

By comparing the parts on Orielly's website, I would need MOOG part numbers ES3248RT, DS1308T, DS1309, and ES3249RT which total 387. 96 for the stock "Y" setup.



Or if I understand this correctly I could get the following part numbers listed for a 1999 3500 and it would be a direct swap? Part numbers ES3496, ES3497, DS1456, and DS1459 which total 363. 96 for the "T" setup



So if I'm understanding this right I could upgrade to a newer design that is better and cheaper? Please let me know if this is correct information



Thanks,

12Vmudder

look up the same part # at rockauto you will be at about $300. 00. They have the best prices. Go for the T steering you can't go wrong.



Hilda

 

[12Vmudder]

Thanks everybody for your help getting all these parts figured out that I need to get... I've got almost everything on order and some of the stuff has already arrived... Once everything comes in next week I'll begin the project... Once I know for sure what all I bought I will post a list of parts and part numbers of what I bought for anybody that might be wanting to do some of the same stuff

-12Vmudder

 

[12Vmudder]

It has begun....

Yesterday morning 4/12/08 I started the front end rebuild on my truck after I blew the headgasket while driving to my buddies shop to do the work. . but that is being discussed in a different thread...

I think I have done a good job picking out the best and most durable parts to rebuild a front end like this and will be able to talk more about the parts I bought once I have them installed and have the truck running. . Right now all I have done is take everything out from under the truck and I actually have the axle sitting on some jackstands off to the side. .

Here is my list of parts, part numbers, purchase locations, and prices... If anyone has any questions at all feel free to ask and I will help you as much as I can...

Steering box... . PSC Motorsports... ... SG-841M... ... $450. 92 - $100 core

DSS... ... ... ... ... Enterprise Engine... ... DSS0019402-4. .
Solid Steel Ind. conversion bracket... . EE..... TBK2029402-4. .
Solid Steel Ind. Adj Track bar. . EE. . DAT3029402-4... all 3 items for $711. 50

Bilstein 5100 x 4... Top Gun Customz...
Skyjacker Coil Springs ... Top Gun Customz... D25
Skyjacker dual steering stabilizer... TGC... . all 3 items for $637. 00

Control Arm Bushings... Energy Suspension parts... 5. 3120. .
Sway Bar Bushings... ... ESP... ... ... ... ... ... ... ... ... ... . 5. 5126. . both for $108. 91

MOOG Upper ball joint x 2... Rockauto... . K80026
MOOG Lower ball joint x 2... Rockauto... . K8607T
MOOG Sway Bar End Link x 2. . RA... ... ... K7280
Precision Wheel U-Joint x 2... . RA... ... ... . 374
1 ton rear wheel cylinder x 2. . RA... ... ... . W79767
MOOG 1999 3500 "T" steering setup Part numbers
ES3496, ES3497, DS1456, DS1459, ES2012S, ES3498S
The Rock auto total price was $723. 86

Drilled slotted hi perf rotor. . left hand side... NAPA. . PR86324L
Drilled slotted hi perf rotor. . right hand side NAPA. . PR86324R
severe duty metallic pads... NAPA... SD7339M... ... ... ... ... ... ... all for $359. 30

Steering shaft... Borgeson... Summit racing... . BORG-950... $275. 70

Thats all I have written down as of now but I will update as things go along

Thanks,
12Vmudder

 

[CMacDonald]

Steering shaft... Borgeson... Summit racing... . BORG-950... $275. 70





I got mine from EBay for $210. 00 and have since seen them on there for $195. 00

 

[dseabaugh]

Ok, you guys have me confused. Are you saying that you are ordering parts from Rock auto for a 3500 4X4 and putting them on a 2500 for stronger steering?

 

[12Vmudder]

Yep thats exactly right... The part numbers MOOG 1999 3500 "T" steering setup Part numbers
ES3496, ES3497, DS1456, DS1459, ES2012S, ES3498S

those are all the components that you need to have a complete "T" setup

12Vmudder