96 F150 solid axle swap
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New User
Joined: Apr 2012
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From: Helena, MT
Dana 44, Dana 60, 35" tires, 40" tires... none of this stuff matters and no one can give you good advice without knowing:
- What size tires you plan on running
- What gears
- How much horsepower
- What you mean by "off road use". Rock crawling has much different requirements than a trail through the woods with an occasional mud puddle.
- What size tires you plan on running
- What gears
- How much horsepower
- What you mean by "off road use". Rock crawling has much different requirements than a trail through the woods with an occasional mud puddle.
-It's has the stock gears right now but wanted to put 4.10 gears in it.
-Mostly stock right now I want to rebuild engine down the road and do some mods for more horsepower but not really sure how much.
-I want to climb hills, go through some mud pits, take it hunting and just have a good all around off road truck thats street legal.
Post Fiend
Joined: Mar 2002
Posts: 19,402
Likes: 38
From: Bonita Springs FL
You do not need a Dana 60 for what you want. A solid Dana 44 out of a 78/79 F-150 or Bronco would be best for you. With those tires I would run 4.11 or maybe 4.56 gears if you have overdrive. The rear would be fine the way it is BUT I would probably use a c-clip eliminator clip kit just in case.
Senior User
Joined: Jun 2009
Posts: 323
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From: Durham, CA
76-77 F-150 will have a disc brake high pinion 44 with welded on C wedges and 1/2" thick axle tubes. 78-79 F-150s/ Broncos will have cast on wedges & 3/8" thick tubes, not that any of it makes any difference for your application but just some added info.
Personally, I'd have absolutely no problem in running a 1/2 ton axle for what you want and any of the above would be a great donor for ya. I'm building a rig for the rocks right now on 77 F-150 1/2 ton gear and plan to run 39.5" tires but I'm a finesse driver that has enjoyed offroading all my life and am confident in my abilities to NOT break my junk...
Personally, I'd have absolutely no problem in running a 1/2 ton axle for what you want and any of the above would be a great donor for ya. I'm building a rig for the rocks right now on 77 F-150 1/2 ton gear and plan to run 39.5" tires but I'm a finesse driver that has enjoyed offroading all my life and am confident in my abilities to NOT break my junk...
Post Fiend
Joined: Mar 2002
Posts: 19,402
Likes: 38
From: Bonita Springs FL
Personally, I'd have absolutely no problem in running a 1/2 ton axle for what you want and any of the above would be a great donor for ya. I'm building a rig for the rocks right now on 77 F-150 1/2 ton gear and plan to run 39.5" tires but I'm a finesse driver that has enjoyed offroading all my life and am confident in my abilities to NOT break my junk...
I don't care how good you think you are - bring lots of extra parts.
Junior User
Joined: Apr 2012
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You do not need a Dana 60 for what you want. A solid Dana 44 out of a 78/79 F-150 or Bronco would be best for you. With those tires I would run 4.11 or maybe 4.56 gears if you have overdrive. The rear would be fine the way it is BUT I would probably use a c-clip eliminator clip kit just in case.
Post Fiend
Joined: Mar 2002
Posts: 19,402
Likes: 38
From: Bonita Springs FL
The thing about a c-clip axle like the Ford 8.8" is that the c-clip is the only thing holding the axle shaft, flange, brake drum and wheel in the axle tube. If the axle breaks (not uncommon with larger tires) that whole wheel will walk right off. A c-clip eliminator clip solves that problem.
Senior User
Joined: Jun 2009
Posts: 323
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From: Durham, CA
Tires are only 13.5" wide too so that'll be much less stressful on the components than some big fatties. Also this rig will have a final crawl ratio of around 128:1 so I won't really even need to be on the throttle (NP435, NP203/205 doubler, 4.88 gears f/r). Wheeled my buddies rig through the Rubicon this past summer on similar running gear without so much as a hickup & he's run harder trails without braking any of his 1/2 ton stuff.
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Post Fiend
Joined: Mar 2002
Posts: 19,402
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From: Bonita Springs FL
Well, I do have Superior Evolution series Chromos in front w/ Ox joints & plenty of spare hubs. Tires are only 13.5" wide too so that'll be much less stressful on the components than some big fatties. Also this rig will have a final crawl ratio of around 128:1 so I won't really even need to be on the throttle (NP435, NP203/205 doubler, 4.88 gears f/r). Wheeled my buddies rig through the Rubicon this past summer on similar running gear without so much as a hickup & he's run harder trails without braking any of his 1/2 ton stuff.
Tires are only 13.5" wide too so that'll be much less stressful on the components than some big fatties. Also this rig will have a final crawl ratio of around 128:1 so I won't really even need to be on the throttle (NP435, NP203/205 doubler, 4.88 gears f/r). Wheeled my buddies rig through the Rubicon this past summer on similar running gear without so much as a hickup & he's run harder trails without braking any of his 1/2 ton stuff.
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New User
Joined: Apr 2012
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From: Helena, MT
My best choice would be a Dana 44 hp reverse cut gearing on driver's side out of a 77-79 F-150 or 78-79 Bronco right? This axle should come already with disc brakes right? Then seems like everyone is talking about somehow using chevy TRE? Do leaf springs only get used for 3/4 ton front ends?
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Joined: Apr 2011
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From: orange ma
My best choice would be a Dana 44 hp reverse cut gearing on driver's side out of a 77-79 F-150 or 78-79 Bronco right? This axle should come already with disc brakes right? Then seems like everyone is talking about somehow using chevy TRE? Do leaf springs only get used for 3/4 ton front ends?
Fleet Mechanic
Joined: Jun 2011
Posts: 1,324
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From: Conway, South Carolina
My best choice would be a Dana 44 hp reverse cut gearing on driver's side out of a 77-79 F-150 or 78-79 Bronco right? This axle should come already with disc brakes right? Then seems like everyone is talking about somehow using chevy TRE? Do leaf springs only get used for 3/4 ton front ends?
People use chevy TRE because they then can use 1 ton steering tie rod.
Leaf springs came on 3/4 ton trucks and larger EXCEPT for the later 70's Supercab 4x4 F150's. They came with a leaf spring hung Dana 44.
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New User
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From: Helena, MT
My 96 F-150 is a single cab short box. Would the supercab's leaf sprung Dana 44 work under my truck? What fabrication would be needed if any?
Post Fiend
Joined: Mar 2002
Posts: 19,402
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From: Bonita Springs FL
It would work, but there will definitely be some fab work. How much depends on too many factors to list. If you have crumple zones on your frame rails in front you may want to cut and replace them. You will definitely need to mount spring hangers and shackles.
Fleet Mechanic
Joined: Jun 2011
Posts: 1,324
Likes: 3
From: Conway, South Carolina
Like Andym said, it will work, but its lots of work. Plus the leaf spring Dana 44 is alot rare than the coil spring Dana 44.
I have a 89 Supercab f150. I just went with the coil spring Dana 44.
I have a 89 Supercab f150. I just went with the coil spring Dana 44.
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