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Fitting 2002 aluminum rims on a 1996 truck - both trucks are a 2500.
Old 07-12-2004, 09:45 AM   #1 (permalink)
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Join Date: Jul 2001
Location: Timberville, VA
Posts: 450
Fitting 2002 aluminum rims on a 1996 truck - both trucks are a 2500.

I did some searching on the site to find out will a 2002 2500 series aluminum rim fit on my 1996 2500 truck.

If you do a search you will find a LOT of posts regarding this topic - such as:

2002 aluminum rims on 96 truck..

01 alloy's don't fit over 94 drums


Here is what I did:

I used fellow TDR member JPittinger's advice and did the following: Jack up the vehicle, take off rear tires/rims, install 2 lug nuts to hold the drum on. Start the truck, put it in 1st and low range of the transfer case - this makes the drums turn REAL SLOW. If you have an auto, you may not be able to do this - whatever you do - make sure the drums turn REAL SLOW so not to hurt yourself. I then used a 4 1/2" grinder to remove metal from the outside of the rim so that the new rims would fit. If I had the time would I do this again - maybe. If you have the time to take the drums to a machine shop to have them turned - That would be much faster and no where near as messy (grinding dust everywhere).

The approximate dimensions of the rim's outer lip width was .325 before - and approx .25" after - note - these measurements were not real accurate since I don't have accurate instruments!!

After I did this, I checked the rims on a balancer. They were off just a tad - most people wouldn't even notice (one was .1 oz the other was .2 oz). If you have a balancer - go ahead and true them up.

Then I installed the rear rims - yes, it is a tight fit. Make sure you remove enough metal from the drum to allow for some expansion of the drum. I have about 1/16" clearance.

The front bolted on w/o any problem - BUT you need to check clearance of the brake lines. I found the right side to be fine. The left side I had to bend the hose bracket to make sure the tire wouldn't rub on the hose when turning. According to one of the attached posts - there are steering interference problems that need to be addressed in the 98-99 trucks

Attached are a couple of photos.

Good luck and hope this helps!

Dan
Attached Images
File Type: jpg drum-compare-2.jpg (9.3 KB, 911 views)
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1996 Reg Cab 2500, 5spd, 4x4, K&N, Plate slid forward, no muff - 4" exh from cat back, 158,000 mi, 3:54's, Ranchero 9000's, dead KDP, Homemade headache rack & removable front pushbars, R&K side tool boxes, 14.75 timing
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