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Old September 5th, 2008, 09:37 AM   #1
fsumotorhead
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Default Ford Ton TTB to Ton 8-Lug conversion

For those that are interested.

Before we attempted this, there wasn’t a whole lot of info out there other than it can be done with Chevy stuff. ton TTB cannot be converted to 8 lug using ford parts, at least not anyway that I’m aware of.

This is a quick overview of the parts required to convert a ton TTB setup to an 8 lug ton setup.

After replacing the rear axle with a ford/sterling 10.25 in the ’94 Bronco, the front needed to match bolt patterns so we would only need to carry one spare tire. After lots of research and a few calculations as to cost, utilizing as many stock components as possible was best.

Sure some may argue that a SAS was a better option, but seeing we already had most of the donor parts laying around for the TTB conversion, it would be way to expensive to SAS it. We already had a dead F-250 heavy duty 4x4 donor laying around, that’s where most of the parts came from.

F-250 parts truck $500
misc front service parts $200
GM 10 bolt 8 lug axle used $100

Total cost of both axle swaps together was ~$800-900

Here are the parts required:

Ton 8-Lug conversion parts list
1982-1996 Ford Bronco/ F-150 4WD

Front Axle Parts

Ford ball joints, inner axle shafts, knuckle U joints, drive shaft, and steering knuckles are stock components for a 1994 Ford Bronco without 4WABS.

TTB third member is a Dana 50 from a ’93 F-250 Heavy Duty

8 lug parts are from a 1988 ton Chevy Suburban, listed below:
  • Spindle studs through knuckle
  • Spindles
  • Caliper Brackets
  • Stub shafts
  • Hubs
  • Wheel bearings
  • Grease Seals
  • Rotors
  • Calipers
  • Wheel Studs
  • Locking Hubs
The steering knuckles need modification to work with the Chevy backing plates/ caliper bracket. The ears for the stock ford caliper pins need to be cut off. We used a cutoff tool, the ground them smooth.

The ford spindle studs need to be replaced with the longer Chevy ones.


Brake Parts
  • Brake Master Cylinder and Booster from 1995 Ford F-350
  • All brake Lines and hoses are stock components for 1994 Ford Bronco
The holes for the banjo bolts need to be slightly enlarged with a drill bit to clear the Chevy banjo bolts.

This truck was converted back in March and has had about 5K miles put on the current setup so far with no problems reported to date.

The only pics I have are of the final result and they kinda suck, I wish I would have taken some during the initial build, but didn’t.

It’s pretty straight forward and could be easily accomplished in a day or two if you have all the parts already.




Last edited by fsumotorhead; October 16th, 2013 at 09:31 AM.
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Old September 5th, 2008, 05:17 PM   #2
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http://www.off-road.com/trucks4x4/ar....jsp?id=198393
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Old September 6th, 2008, 01:11 PM   #3
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Quote:
Originally Posted by insaneoffroader View Post


same idea i used!

it works great, easier than anticipated
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Old December 17th, 2008, 05:19 PM   #4
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Here's some more pics, notice the pics of the caliper ears cut off.







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Old December 17th, 2008, 08:24 PM   #5
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Kick ass post...props for keeping TTB....I want to do this with one of my rangers - put 44 outers on the 35 for better wheel bearing spacing and brakes...I know it can be done, just need the $$ and time
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Old January 31st, 2009, 02:48 AM   #6
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what brake lines did you use?
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Old January 31st, 2009, 01:39 PM   #7
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i used the stock brake hoses, i hade to use a drill bil to open the banjo bolt hole up a tiny bit. I think it was like a 7/16 size bit, but can't remember for sure.
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Old February 14th, 2009, 08:17 PM   #8
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do you know exactly what calipers you used?

like jb5 or jb7?

I ask cause I got some from autozone, and traded in the old ones as cores, and the hoses don't look like then can even fit up to the calipers
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Old February 15th, 2009, 09:56 AM   #9
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i believe the calipers were from an '85 K-10.

The line is rectangular, but that doesn't matter, the crush washer seats fine on the caliper.
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