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Old 02-19-2019, 09:18 AM   #1
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Sterling upgrade

Hey all. I was looking into a sterling upgrade and what was necessary for it. Mine is a 2x4 not a 4x4. I tried to the search option to see what is posted already about it and didn’t find too much. Is there a build thread on this already? I’m putting a 2011 RSC f250 rear axle into a 2011 RSC E350. These are my obvious questions

1. Move spring perches and shock mounts
2. MG said ebrake cables should line up but I need to make a new section.
3. Replace E350 driveshaft flange with f350. I think they use the same unjoint so that should be a direct swap?
4. Will the hard E350 brake lines bolt into the f350 rubber lines?
5. Does anyone know if they used the same RSC plugs for the abs wheel sensors and top of pumpkin? So that would just be a plug unplug deal.
6. 8x170 to 8x6.5 wheel adapters.

Am I missing anything. I really want to get a good overview to see if this is relatively easy or not.
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Old 02-19-2019, 02:43 PM   #2
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My van is a 2010 E150 but since it came as a cargo van it got the e250 chassis. I swapped a 2014 f250 rear axle in the back and most of your list looks good. The hard lines probably wont just connect right up, I had to measure the size and threads on the van and axle sides and get a thread adaptor for the one line. Easy to do just means you get brake fluid on you while you measure.
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Old 02-19-2019, 03:27 PM   #3
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Is your van a RSC?
4x4?
Did you get perches from ballistic? Do you know part numbers?
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Old 02-19-2019, 03:39 PM   #4
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Yes. It just has the two wheel sensors and those all connected right up. I used the sterling sensor lines and connected them at the top. I dont think they were any different at the connections. If they were it was an easy plug swap.
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Old 02-19-2019, 06:03 PM   #5
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Sorry. A few more questions. Was yours a 4x4? If not did you have to shave the driveshaft? Or did you just put the flange on the end of the E350 shaft?

Where did you buy perches and shock mounts from? Do you have part numbers?

Did you just replace the center section of the e brake assembly?

What gear did you go with?
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Old 02-19-2019, 06:55 PM   #6
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It was 2wd and I made it 4wd and put the rear axle under it. I had the rear driveshaft made since it was coming from a t-case

I wanna say I got my perches and stuff from ballistic fab? It's nothing fancy just truck spring perches.

I used all stock ford f250 e brake lines for my axle. But I think I went with the wide axle e brake lines.

It just has stock 3:73 gears but I would go 4:10 at minimum.
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Old 02-20-2019, 12:57 AM   #7
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I'm probably bringing up an issue that you've already thought through, but I don't believe that I saw it addressed here? I've seen plenty of people do the inverse of what you're proposing (E series rear axle + adapters to match their converted f series 4x4 front end) but I can't say I've seen anyone first hand that adapted the f series rear back to 8 on 6.5? I know I quickly ruled it out before building up my (much older) full float Dana 60 on my 2wd.

I guess what I'm getting at is: isn't the Sterling already several inches wider than an e series Dana 60? Then adding the necessary width of the adapters/spacers, you'll end up adding another couple inches, right? Do you know the WMS-WMS of each axle already? Is the Sterling + adapters going to be too wide?
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Old 02-20-2019, 08:39 AM   #8
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I believe it’s going to be wider track than front by about 1.5” on each side. I believe the sterling is comparable to the cutaway 72” rear axle.

My conundrum is this. I have a semi float loaded to max weight. I would like to go full float but the cutaway axles are hard to find and are expensive. I found a 2011 4.30 gear e locker 15k miles sterling rotor to rotor for $600. I’m trying to see if I can make that work.

I figured it would track like a dually. And add some fender flares? Would love to find some universal 8 lug wheels so it didn’t make a difference.

I hope to go 4x4 at some point but is not realistic now.

In your case you had the FF already in there. I do not.

On the other hand if I go cutaway and then go 4x4 I will need wheel adapters that put me to that same width.

Open to suggestions.
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Old 03-25-2019, 10:45 AM   #9
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Got it in. Lots of little issues here and there. But thanks to some amazing members here I was able to do it. Got to replace the two rear calipers and then I can take it out. Rear axle doesn’t seem abnoxiously wide. Total width is 73” vs 69.5 or so front and 66.7 rear.
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