Im trying to do a little research on the subject. Would the knuckles from a Dana 50 TTB(1990 F250) fit on a Dana 50 Solid axle from an Excursion? Im wondering since I can get a Solid Dana 50 for a reasonable price but it is missing the driver side knuckle. Plus I would like to retain the 8x6.5 lug pattern. Also, the inner driver side axle shaft is missing, so would the axle from the 90 fit into the solid dana 50? And please refrain from recommending doing a Dana 60 swap instead. Around here they are hard to find and expensive. I want to keep this a low buck swap...thanks in advance!!!

 

I'm going to venture a guess that it won't work.
If you don't want a D60, try finding a D44HD from a 78 or 79 F250. These axles have a high pinion, and are fairly robust. I used one for the SAS on my 84 F250, and am using another one on my 72 F100 4x4 project. They can sometimes be found in the $100-$200 range, since they aren't a D60. Many simply get sent off to scrap.

 

i already have a d44 from a 79 supercab leaf spring axle but it is 5 lug...the d50 ttb is stout enough but i would still prefer a solid axle....plus its a diesel and i dont know if the d44 would hold up to the weight and haulin stuff...i was under the impression the solid d50 was essentially a dana 44 in a dana 60 housing...and that the knuckles on the d50 ttb was the same as a dana 60...so perhaps they would interchange a bit...

 

I understand that the spindles are much different. There is a raised lip on the backside of each spindle, but the TTB spindle has a much deeper lip, partly due to caliper bracket retention, and that the solid axle spindle has a much smaller raised edge.
The TTB spindle will not go on the solid axle, but the solid axle spindle will fit the TTB knuckle. Confusing I know, but even doing it this way does not provide adequate penetration of the caliper bracket.
Now, lets go a step further and discuss the spring perches on the late model Dana 50.
The driver side spring perch is cast into the differential, and this axle also utilizes a short driver side axle. This really eliminates the use of this axle using stock configuration springs. You will have to relocate the spring hangers and the springs, about 2.5 inches outboard to even accomodate this axle.
Next is the metric bolt pattern of the hubs, and perhaps this is why you are wanting to use the TTB front hardware, and perhaps this is also why you are attempting to use this hardware, and that is to eliminate the troublesome unit bearings?????
Unfortunately this does not work, and would require more in modification than it is worth.

How thick are your axle tubes? I do believe that you are fine using the D44, even under the diesel. I believe that the limiting factor will be the actual strength of the shafts and not of the housing. The added torque of the diesel will probably take more of a toll on the axles shafts rather than the axle tubes.

As far as making your D44 8 lug, this is simple by finding junk yard parts. Simply replace your hardware from the knuckle out, and you have an 8 lug front end.
Converting a Dana 50 sounds like more work than it is worth. No real reward there.

 

you have made a good point....but you mention the spindles are different, but what about the knuckles? also, instead of relocating the springs, would it be possible to just relocate the perches? i mean this does sound like a lot of more work and only yield marginal results... i was just curious if it was even plausible.....i can get ahold of a couple d44 solid/8 lugs for near dirt cheap...so for the time being, that may be my only recourse....thanks alot for you input!!!.....