Ok gang, I've posted on this topic before, but after doing much research and speaking with a couple of guru's I'm looking to seal the deal on a decision. On my 98 Durango I have a front half ton SA Ford D44, and a rear Ford 9" (I never expected to go over 38.5's). The way things are looking I'll be going to 46" slickey mickeys, or 49" IROKS. Below I have listed some ideas and partial questions for my plans. Any insight is appreciated. This truck is not wheeled often and only locally which is sand/mud/trail riding. NO ROCKS!!

A. Through researching, I've found the biggest differences between a half ton and a one ton (strength factor), is the fact that one tons have thicker housings, and there a stronger kingpin design. I was thinking of going to F250 Flat top knuckles, a spicer balljoint, and trussing the hell outta this D44, along with trussing the rear Ford 9". Aside from it only being a 5 lug setup, shouldnt this be enough to get the job done or will I have to dodge speed bumps in fear of breaking something? Also, is there a manufacturer that sells a truss kit or will I need to build one?

B. I was thinking of Utilizing the rear Ford 9 and upgrading to a one-ton front end. This leaves with the dilemma of a 8 lug front, and a 5 lug rear. So, is there anything on the market or trick to converting a front one ton to 5 lug, or a rear Ford 9" to 8 lug?

Keep in mind this wont be to hard of a wheeler, I'm going to get another suzuki samurai as a DD and my beater. So the durango will be a every once in a while wheeler and nothing more than the extremity of Sand dunes and mud pits and some trail riding. I figured since some one tons are 31 spline and the roughest time on axleshafts are at full turn with a locker (I have a tru-trac front) on rocks (or somewhere with hard traction), that with trussing and spicer balljoints with some forged axles that it would take the stress of 46's-49's.

 

46's or 49's on a 1/2 ton D44 will barely get you to the mall and back. In addition to the thin tubes you also have the weak knuckles and small axle shafts that can't handle the torque those tires are going to put on things. My suggestion would be to look for an F350 being parted out. Buy it up and swap in the D70/D60 combo or a Sterling 10.25 rearend if that's what it comes with. Even the 1 ton running gear won't keep up with those 49's for a serious wheeler but for what you're planning on doing they should be adaquate. You should also make sure you get a kingpin D60 front so that crossover steering will be easy to adapt.