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I have a 76 f-250 with 97 12 valve cummins. I have 37" tires and currently have the stock axles. A Heavy duty d44 that was rebuilt about 7 years ago. I don't know axles very well and want to know what you guys think.
Get some alloy axle shafts for the hd d44?
or
Find a D60?
'76 F250...That would give you the open knuckle front end which uses the ball joints instead of the closed knuckle design used in the '75. Correct?
I believe: The Dana 44 is either the standard or the HD (eight lug pattern). You should have 8 lugs. Yours may also have a "low pinion". I personally hate these. Mine always leaked and the driveshaft sat a lot lower to the ground. My buddy has a "high pinion" 44.
If yours is of closed knuckle design I would ditch it for a Dana 60. Open knuckle? You'll have to decide if the pinion thing applies to you or is an issue to you.
I cannot give you an honestly correct answer about the strength between the 44 or 60 in regards to the axle shafts. Although I have heard...The major difference between the 44 and the 60 is the size of the bearings and its load carrying capacity. Perhaps if you could find some scematics which give you the dia of standard internal axle shafts of the 44 ond 60.
The D44HD has much thicker axle tubes, and larger diameter hub bearings than the D44 used in the F100/F150 and Bronco, but it still uses the same universal joints and inner shafts. While it does have a higher load carrying capacity and is a fairly durable axle, when you start getting into situations where the front wheels see a lot of torque, then those shafts and universals go pretty quick. The Cummins 12v is a bit more weight than that axle was intended to carry as well, so when you combine high weight with the traction of large tires and the torque of the Cummins, that axle will not last very long at all.
There a decent axle, As long as your not jumping it off road it should be fine. If it has the big hubs on it thats a plus...With aftermarket shafts they are supposedly as strong as a stock d60. The unfortunate thing is they are low pinion. Drive shaft is much more in the way. I found that out the hard way in my brothers truck. Drove over a curb into a ditch and the drive shaft struck the curb and bent it. Got it all sorted out though, learned a good lesson from that. Be careful with low pinions and dont screw around in someone elses truck when they trust you enough to let you use it.
What would bother me more than anything is it sitting on ball joints as opposed to the Dana 60's big tapered roller bearings and king pin. Later Dana 60's used ball joints as well and would require a lot of fabrication to get under your truck. Look for a '78-'79 axle if you are going to get one, they will bolt right up.