So,as some of you have read in my previous posts I am going upgrade crazy on my rig.I have always wanted to build a truck for myself I already built my dream harley,took me 5 years,20000 bucks (some money I had most I didn't took alot of sacrifices)but It got totaled,tractor trailer cut across 5 lanes because he missed an exit,hit me,and then left me for dead in a lane on the interstate.
So,I got the plant figured out,got the dana 60 for the 44 swap now it's to the rear.The Dana 60 I got is a 3:54 ratio,I don't have alot of 4 wheel drive experience(I am a firefighter in NYC and a heavy truck mechanic by trade)so I have decided to upgrade my rear(which is a Dana 61)instead of changing the ratios I have decided just to change to whole rear to a beefier one.Right now it's my dailly driver and has never been off road(I wasn't able to walk for 2 years and I got hit a month after I got it).this is all going to change soon thoughSo first,I have the dana 44 in my rig,the regular one I think(I have a '75 f250 with a np435/np205)Whats involved with the swap?I have the hydraulic power assist steering which I would like to keep.On my axle one side of the ram mounts to a heavier bracket on the pumpkin(which can be unbolted) and the other side to the tie rod.On the 60 I have it has a stabilizer that mounts to the shock bracket and the other side to the tie rod.Should I just put the ram there?Will the bracket be strong enough or should I just machine the existing bracket to fit around the larger tube and stick with the original tie rod set up?What about the rear,I have 2 choices.One is a Dana 70 and the other is a Sterling.I would like to stay away from a metric bolt pattern so all the wheels match.If I get a rear with a 3:55 ratio will it work with the front 3:54 ratio.If I remember correctly my 77 had a 4:09 front and a 4:10 rear.I am converting to 4 wheel disc so the brakes aren't a problem.I would also like to go with the hydroboost setup due to valve cover clearence issues.What year/model is best?I think I should have a master with 2 equal volumes.What about the proportioning valve?Should I buy an aftermarket?Any insight would be appreciated,thanks

 

well, first off I think the rear that you have now is a D60, not 61. if I'm correct the 61s came in half-tons. I would go with the D70 for the rearend.

the 3.55 ratio should work. I think that's how the gears always are (different in front).

sorry that I can't help a lot with this. if you need help contact 75F350; he knows a bunch about this kind of stuff.

sounds like a great project. good luck!