I have a 95 f-150 4x4 that came stock with 3.31 gears in it. I decided to go with 4.10 gears after the lift and 33" tires. i have had the 4.10's in the rear for quite some time now and have been running without a front driveshaft since i havent had any time to take care of the front. Since it is my daily driver i cant afford to get halfway through it and finish another day, so i decided i would try to find a used dana 44 IFS housing and then i could buy gears and an open carrier and set up the gears completely without touching my truck, and then just swap center sections out and it would only take 2 hours. So i got a used housing from I believe it was out of a 1980 bronco. The gears are installed and all set up, and i took the front end out of my truck last night to swap, but my problem is that i didnt realize there was another bearing on the outside of the case that supports the right stub shaft, i thoght it was just the seal, but there is a bearing behind it, and all i bought was the seal. No problem i thought, since i have my stock diff out of the truck, i can pull the bearing out of there. That is when i realized that the bore on the right side of the housing where the bearing and seal go is much larger in diameter than that of the housing originally in my 95. So i couldnt put it together because i didnt have to parts. so today i get the correct seal and bearing for the 1980 D44IFS. The seal is the right size for the bore and so is the bearing. The problem now is that the inner diameter of the correct bearing is too small for my axle shaft to slide through it, and even if it did slide through, the inner diameter of the seal is much larger than my shaft so it wouldnt be sealing anything! So i think my problem now lies in my axle shaft. I think maybe the earlier D44 IFS right side stub shafts had a thinner land for the bearing race so it can slide though this bearing, but after the bearing land i believe tose shafts got larger in size to fill the large hole in the seal. So my question finally is, am i right in assuming this, and if so, can i buy the 2 piece right side axle set for an older truck and install it in mine with no problem? or will it slide into my diff fine but then it wont work with my late model hud or spindle if they may be different. Any help is greatly appreciated.
-John

 

Personally what I would do, and it will save you the mix match of parts you have now. Take the 4.10 diff/carrier out of the 80Bronco( if that's even what it is) and put it in the 95, and get them set up. Return the parts that you can(if you can) or exchange them for the right ones for the 95.

If you have to drive your truck, just pop the outer ujoint apart and put the outer shaft back in the hub.