I'm in the process of doing a Cummins conversion in my 79 F250. I'm a little concerned about all the extra weight on the Dana 44 up front and I'm having a hell of a time finding a Dana 60 front up here in Saskatchewan.

Is there any other font differential as heavy or heavier than the 60 front that is about the right width with a driver's side drop? Fabrication isn't a problem.

Any input is appreciated!

 

The overall widths are all pretty similar. It's the spring perch and pumpkin location that is the problem. I have heard of guys re tubing later dana 60 kingpin fronts to get the proper spacing.

 

There are several articles in these forums about doing such a engine swap, you might like to check them out to see what they have done.

 

Copy and past info from a fellow FTE member.

"D44-D60 But you will have a hard time finding a 60 with the 32.5" spring spacing, it'll have to be from a dentside. The '86+ axles are spaced at 36", but are more common. Honestly the price you pay for one is way over rated. I happened to get one and put it in my truck but it is just bragging rights to say "Yeah...I got a D60 front axle." It really is just a bragging point and are over rated unless you continually are beating on it so hard you a tearing your D44 apart all the time.
The truths:
Yes it is heavier...doesn't do much but slow your truck down.
Yes it has a bigger ring gear...haven't broke yours so why need to go bigger?
Yes it has bigger u-joint...good news is that likely won’t break on you.
The pitfall:
The outer shafts are the same diameter as the outer shafts on a D44 (just a different spline count). Instead of maybe breaking a u-joint you will likely break an outer shaft and good luck finding a cheap replacement.
The D44 held up for you for now, why change it? Also spare parts for the 44 are cheap. If you have 3:55 gears now and want to find 4.11s just find a D44 with 4.11s in already. I wouldn't pay more than $200 for a D44 front...they are very common. One questions for this would be what size tire are you running? For off road use the D44 is usually good 35" and under tires (yes there are many exceptions for this). If you rebuild the D44, do you plan on putting in after market (stronger) axle shafts and u-joints (or do you already have them). Load rating tests show that a fully upgraded D44 axle with good aftermarket shafts (there are LOTS to choose from and some are far better than others) is about equal to a stock D60 with 35 spline outer stubs. Ok now you just upgraded your axle shafts... what does your current ring and pinion look like? If you are eating up teeth or snapping pinion shafts there is really no fix for this but to go to a D60... well there is one possible option and that’s a Dana 50 which is a kit to drop in D50 gears into a D44, bigger ring gear but same pinion shaft diameter. If you are going to regear and going to keep the D44 this might be a good time to look at this option for increased strength. Last question is... with the plow on the front and any extra weight are you over the D44's load rating? If you are really working it hard do you know if your D44 is still strait and are you overloading the wheel bearings? Might be time to weigh the front half of your truck and see where you are at. An axle truss might help but I'd say if you are past the 44's weight I'd move on to a 60."

 

The Dana 44 under my Cummins is holding up just fine with 35" tires, and it's been driven around for a little more than a year now. I dont go easy on it, but it doesn't see much off pavement any more either.

 

Thanks for the input everyone. The truck wont be getting over 35s and will be occasionally pulling or being used for hunting season in the field so I think the 44 should be okay. Unless a 60 pops up somewhere ill use the the 44.

Does anyone have preferences on brands of aftermarket 44 parts? Highest quality? Biggest bang for your buck?

 

Ck out this guys thread (long, entertaining and full of info) and an answer to that very question near the end of the thread around post # 300.

https://www.ford-trucks.com/forums/1...cab-frame.html

 

Thanks I'll have to check that out.

 

This is incorrect fyi.

I went from a high pinion 44hd to a hp D60 and have mixed feelings about it. The 44 was holding up just fine and was a lot lighter. It was also paid for. My swap cost a small fortune. I do however have the peace of mind a 60 provides. Smashed a deer at 65mph. No worries. When I got my rig the drivers side short axle was broken from the 460. I figure the Cummins would snap one pretty easy.

 

There's no such thing...unless you made it yourself, out of a low pinion D44hd and a 78/79 hp D44.

 

Haha. Never sure what to call a High Pinion 44 with the 8 lug outers. I always just called it heavy duty because it's heavier duty than it's 5 lug counter part.

 

Great D60 info place... BillaVista.com-Dana 60 Front Axle Bible Tech Article by BillaVista

Pretty much a ton of info overall. BillaVista.com - Offroad & 4X4 Tech Articles by BillaVista

 

all in good fun.

 

No problem man I knew you were ribbing me. What do you call the 78-79 high pinion 44 with the 8 lug outers versus the F150/Bronco 78-79 44? Is HD not right or am I too tired to get your joke?

 

The D44hd is specific to the hiboy, and if/when I refer to 1/2ton equipment I'll throw the term "coil sprung" in for clarification.