96 F150 solid axle swap
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New User
Joined: Apr 2012
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From: Helena, MT
96 F150 solid axle swap
I have a 96 F150 4x4 with ifs and im looking into swapping to a solid axle. What year donor truck should I look for to have the sturdiest axle for off road use with little fabrication?
Carpenter Local 745
Joined: Apr 2006
Posts: 5,794
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From: on da beach
78-79 F150 or Bronco if using D44.
Also older units may be used, but make sure
It has disc brake set up.
There are companies making upgrades like:
Shock towers
Spring buckets
Extended radius arms
Springs
So, if you have a larger budget
You can get away by just finding a front axle housing.
Also older units may be used, but make sure
It has disc brake set up.
There are companies making upgrades like:
Shock towers
Spring buckets
Extended radius arms
Springs
So, if you have a larger budget
You can get away by just finding a front axle housing.
Fleet Mechanic
Joined: May 2005
Posts: 1,575
Likes: 11
From: Puyallup, WA
Might take a bit more fab, but you can't beat the strength factor.
I also can't see any advantage to go SAS on half ton running gear as you really cannot safely run any bigger tires than you can with a properly setup TTB.
My opinion, David
Junior User
Joined: Apr 2012
Posts: 96
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either a Dana44 or Dana 60 require the same amount of work to swap in, like others have said a d44 isnt much of a upgrade of what you want, as far as d60's go, 78 and newer ford 60's are the best, 78-79 housing have alot of room on the drivers side for control arm mounts, later ones have less but can still work with ease, You can either buy a axle bracket kit or fab your own stuff, also around 92 they went from kingpin to balljoints
Fleet Mechanic
Joined: Jun 2011
Posts: 1,324
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From: Conway, South Carolina
A D44 solid axle is a big upgrade. A D44 TTB, can only handle up to 35" tires on serious off-roading. A D44 solid axle can handle up to 39" tires serious off-roading. Yes, I know people that run 39" and even 40" tires with D44 solid axle, and abuse them.
Anything bigger than 40's I recommend a D60.
A D60 takes more work to swap than a D44, because you can use your TTB coil bucket/shock tower, and it gives you 2" more lift.
Anything bigger than 40's I recommend a D60.
A D60 takes more work to swap than a D44, because you can use your TTB coil bucket/shock tower, and it gives you 2" more lift.
Junior User
Joined: Apr 2012
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A D44 solid axle is a big upgrade. A D44 TTB, can only handle up to 35" tires on serious off-roading. A D44 solid axle can handle up to 39" tires serious off-roading. Yes, I know people that run 39" and even 40" tires with D44 solid axle, and abuse them.
Anything bigger than 40's I recommend a D60.
A D60 takes more work to swap than a D44, because you can use your TTB coil bucket/shock tower, and it gives you 2" more lift.
Anything bigger than 40's I recommend a D60.
A D60 takes more work to swap than a D44, because you can use your TTB coil bucket/shock tower, and it gives you 2" more lift.
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Logistics Pro
Joined: Mar 2011
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From: Central Wisconsin
and thats why i see d44 stuff get constantly broken on lightwieght jeeps on 35-37" tires, i cant recomend anything bigger then a 35 unless you got high dollar axle shafts and ujoints, and explain why i d60 is more work, both axles need the same exact brackets and mounts, only diff is the bolt pattern
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Thread Starter
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New User
Joined: Apr 2012
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From: Helena, MT
I would just find a D44 out of a half ton and throw it in, that way you still have the 5 bolt pattern front and back.[/quote]
How do i know the difference between the dana 44 and the dana 44 HD? Would the stock rear end in my 96 F150 hold up to the offroad or is there a rear end swap I should look into?
How do i know the difference between the dana 44 and the dana 44 HD? Would the stock rear end in my 96 F150 hold up to the offroad or is there a rear end swap I should look into?
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New User
Joined: Apr 2012
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From: Helena, MT
Well if you are looking for the sturdiest axle(s), then junk the half ton stuff as step up to one ton axles.
Might take a bit more fab, but you can't beat the strength factor.
I also can't see any advantage to go SAS on half ton running gear as you really cannot safely run any bigger tires than you can with a properly setup TTB.
My opinion, David
Might take a bit more fab, but you can't beat the strength factor.
I also can't see any advantage to go SAS on half ton running gear as you really cannot safely run any bigger tires than you can with a properly setup TTB.
My opinion, David
Fleet Mechanic
Joined: Jun 2011
Posts: 1,324
Likes: 3
From: Conway, South Carolina
A D44 and D44 HD is exactly the same, except from the knuckles out.
If you have a D44 and want to go 8 lug in the future, you can get HD knuckles and a 10.25 rear axle and bam you got 8 lug.
Also a D44 high pinion solid axle was under the bronco from 78-79, and under the f150 from 77-79. I got mine from a 79 f150 for $150.
If you have a D44 and want to go 8 lug in the future, you can get HD knuckles and a 10.25 rear axle and bam you got 8 lug.
Also a D44 high pinion solid axle was under the bronco from 78-79, and under the f150 from 77-79. I got mine from a 79 f150 for $150.
Logistics Pro
Joined: Mar 2011
Posts: 4,197
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From: Central Wisconsin
Internally yes. The HD will be set up for leaf springs and the Regular one will be set up for coil springs.
So you could have an 8 bolt front end with coil springs eventually if you wanted.
So you could have an 8 bolt front end with coil springs eventually if you wanted.
Post Fiend
Joined: Mar 2002
Posts: 19,402
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From: Bonita Springs FL
- 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.