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How much work would I be in for? I've got a 95 F-150 5.0, and would like to do a solid axle swap. What axles would you recommend? Would a solid axle swap affect the ability to install a lift kit?
The d44's from the mid-late 70's broncos (and f150s i believe) are solid and are a direct bolt on. For a little more money you could swap to the stronger d60, but they are high demand and thus high dollar. It will not affect your ability to install a lift but the lift kit is going to be an entirely different type than the ones for the ttb front ends.
I am going to do both axles on my 84 Bronco, getting all the parts will take time. If you have big $$$$s, go to Bronco Graveyard(one of FTEs sponsors on the top of the page) and get ALL the parts for the front end - 1700.00 - and look for a 9in from a pre 83 truck - that's what I am doing now - I was told look for a 31 spline/ big bearing 9 inch.
I think the 9 inch is very strong, and it is easy to work on.
Do you want 6 lug or 8 lug. Six lug your going to need the 44/9 in combo. The 8.8 is not as strong. But If I was going to have the trouble I would swap in a 10.25/60. The swap should be a direct bolt in I believe. The 60/10.25 or even maybe 10.5 would be a one ton set up. I paid 1k for my 60, I would imagine a 10.25 could be found for 500 or so. Then you need rims and depending or steel/ aluminum your looking at 200-1000.
You wont be able to use the 9inch in the rear of your truck. Due to its lack of a tone ring which works the rear abs, speedo, and how your trans shifts. I thought about it at one point also but its doesnt work.
fullsizebronco.com has more then enough info about sas swaps, and hundreds, if not thousands that have done them.
You can use all the front suspension componets from the 77-79 ford uncluding coil buckets, shock buckets, radius arms and raiuds urm brackets. then order lift coils for the 7-79. Look into what kind of c bushings you'll need. You will have to fabricate a mount for the trac bar.
I completed a solid front axle swap on my 94' F-150 last summer. It was from a Dana 44 from a 79' Bronco. I maintained the coil over to maintain the softer ride. Push our trucks already have the coil buckets. I had a 4" lift already and used the drop down radius arm brackets, made a frame/track bar mount, made a custom track bar. I complete the entire swap with a complete Dana 44 rebuild under $1500. I ordered a 79' Bronco lift from Superlift and it fit everything fine. My best friends throughout this venture were the guys at Broncograveyard.com. They have great customer service and lots of parts for every situation. Let me know if you need more info. I will be posting is all soon. Josh88Ford is right, you can, and I did, save money this route. I think the 44/8.8 combo is good for a weekend warrior/daily driver like myself. Not to hard on the budget.