D44 SAS in 88 F-150 - Ford Bronco Forum
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post #1 of 56 (permalink) Old 09-09-2016, 02:53 PM Thread Starter
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D44 SAS in 88 F-150

I just got all 4 tires back on the ground and thought I would do a write up to share my experience and get some opinions from others. The whole thing started by finding a set of axles out of a 78 F150. The specs on these axles that caught my attention are:
-4.88 gears already installed (new)
-Limited slip D44
-Full spool 9"
-Nodular Strange 3rd member for the 9"
-Disc brakes for the 9"
-4340 chromoly shafts for the D44
-$700

Next I will share cleanup, paint, and prep.
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67galax, BSS and dash_cam like this.

Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #2 of 56 (permalink) Old 09-12-2016, 07:42 AM Thread Starter
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The next thing I did was paint some of the components and the the 9". I sprayed some of the components with Huculiner out of an HVLP harbor freight gun, some rustolium rattle can, and some John Deere Blitz Black. You can see I have the disc brakes install on the 9" too.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #3 of 56 (permalink) Old 09-13-2016, 10:09 AM Thread Starter
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Got the D44 up on the table, opened up the cover and found this mess inside. I had to completely disassemble and and power wash out. I got a track bar and springs from wild horses. After that I got most of the D44 assemble and stored out of the way because of a distraction.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #4 of 56 (permalink) Old 09-16-2016, 10:41 AM Thread Starter
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Thanks to Galax67 I had to wait to get started on the axle swap. I picked up a 351 from him that needed some work.
I spend a few days tearing it down and found a hole in this piston. No worries because I planed to rebuild anyway.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #5 of 56 (permalink) Old 09-16-2016, 01:35 PM
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i thought the hole would be bigger. ever find anything in the oil pan that caused it?

I was born with five senses, and Urgency wasn't one of them
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post #6 of 56 (permalink) Old 09-16-2016, 03:35 PM Thread Starter
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nothing special in the oil pan. Not sure what caused it.

Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #7 of 56 (permalink) Old 09-20-2016, 01:29 PM Thread Starter
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Back to the SAS. I took a couple of measurements before I got started. These measurements are from the ground to the wheel arch with 31" tires. DS is at 35" and PS is at 35.5". The TTB removal went pretty smooth, some bolts broke and a couple of things needed torched. I had everything removed in 1 day with some help from a friend. The biggest surprise was the hole that rusted all the way through the frame on the PS.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #8 of 56 (permalink) Old 09-20-2016, 02:50 PM
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that hole is pretty bad...kind of surprised the frame didn't just snap there..I'm assuming you're going to clean it up and plate over it, right?
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post #9 of 56 (permalink) Old 09-21-2016, 09:30 PM Thread Starter
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Yeah that hole was pretty bad. I had some 1/4 plate that I torched out and welded in place over the hole. Once the welding was done I primed and painted the frame on both sides.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #10 of 56 (permalink) Old 09-22-2016, 04:40 PM
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That's a pretty good score on those axles with all the nice extras.

With the axle still out you should think about replacing those D44 inner seals and spring for some new balljoints if you don't know how many miles the axle had and what size tire was being run.

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post #11 of 56 (permalink) Old 09-22-2016, 09:01 PM
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1984 Full Size Ford Bronco w rebuit 302 and Auto w/OD
Lotsa Rust - Lotsa Noise - Lotsa fabricating
Project for my son and me
Here is the blog of our progress
Project Alpha Bronco
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post #12 of 56 (permalink) Old 09-22-2016, 09:02 PM Thread Starter
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The guy I bought the axles from already changed the ball joint too. While I had the D44 diff apart for cleaning I put new seals in there too.

I feel pretty cool right now. I got comments from Jermil and Shadofax. I have read alot of comments on other post from you guys and really appreciate your input.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #13 of 56 (permalink) Old 09-22-2016, 09:16 PM Thread Starter
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Once everything from the TTB was out and the hole in the frame repaired it became time to start drilling, and drilling, and drilling, and some more drilling, and did I mention drilling. Anyway, once the drilling was done for the coil buckets, track bar mount and shocks, I got to hang from the buckets.

Next I will share my work from the radius arm cross-member.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #14 of 56 (permalink) Old 09-22-2016, 09:17 PM
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Quote:
Originally Posted by Vochy View Post
The guy I bought the axles from already changed the ball joint too. While I had the D44 diff apart for cleaning I put new seals in there too.

I feel pretty cool right now. I got comments from Jermil and Shadofax. I have read alot of comments on other post from you guys and really appreciate your input.


My issue is that I just lack the time these days to get out and look at posts. I've been more involved on the site recently since, matter of fact, Jeremy and I have been contacting each other on a part for his 1356 blues.

I'm also much less of a help these days as I still love driving my truck, but have not been involved in projects, not involved with detailed specs I used to love, many questions I choose not to participate in an answer since I can't remember some of these details around a specific question...figure better to let someone more in the know answer those.

This issue though, I do know you do not want those internal seals leaking right after installing under your truck, and even the best D44 BJ's only last so long once you get to 37's and are wheeling the truck.

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post #15 of 56 (permalink) Old 09-22-2016, 09:31 PM Thread Starter
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I know what you mean about not having the time. This is a project I wanted to start about 5 years ago. However, I got into renovating an old house with my girlfriend. Once the house was done, the girlfriend became a fiance and wedding planning took my time and money. I have always loved wrenching on this truck and it has a ton of sentimental value to me. I am finally in a place where I have some time and money to make it great.

Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #16 of 56 (permalink) Old 09-23-2016, 08:28 AM
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You nailed it..I try to answer the things I'm semi-competent on and steer clear of those I'm not...sad part is I've probably forgotten more than I know at this point..good thing I have my supermotors as a reference..


If you ever have to do ball joints again I recommend these. USA Alloy brand, they are heavy duty, company lists them for jeeps but they work on the Dana44.
PN for the Bronc is 11802



keep the pics coming.


Quote:
Originally Posted by Shadofax View Post


My issue is that I just lack the time these days to get out and look at posts. I've been more involved on the site recently since, matter of fact, Jeremy and I have been contacting each other on a part for his 1356 blues.

I'm also much less of a help these days as I still love driving my truck, but have not been involved in projects, not involved with detailed specs I used to love, many questions I choose not to participate in an answer since I can't remember some of these details around a specific question...figure better to let someone more in the know answer those.

This issue though, I do know you do not want those internal seals leaking right after installing under your truck, and even the best D44 BJ's only last so long once you get to 37's and are wheeling the truck.
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post #17 of 56 (permalink) Old 09-24-2016, 09:47 AM Thread Starter
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I don't have the 78/79 frame side radius arm mounts and don't really care for the way they articulate. I have read how the radius arms put alot of force into the frame so I thought I would fabricate a crossmember out of angle iron for them to mount to. I used 3x4 3/8 angle iron only because I had some laying around from another project. I welded everything with 7018.
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MATCHBOX likes this.

Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #18 of 56 (permalink) Old 09-24-2016, 09:55 AM Thread Starter
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Here are a few more pics of it painted.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #19 of 56 (permalink) Old 10-08-2016, 07:30 AM Thread Starter
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It's been awhile since I had time to post anything, work got really busy the last few weeks. The next thing I had to do was make an adapter for the stock radius arms to a Heim. I used left over DOM from my ruff stuff Y link steering kit. When I slid it over the bayonet of the RA I reilized that it would end up about 4-6" inboard of the frame rail. The solution, heat and leverage to put about a 10 degree bend in the tube. Next I Tig welded in some threaded bungs to screw the Heims into and beveled the other end for welding to the RA.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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post #20 of 56 (permalink) Old 10-08-2016, 10:35 AM Thread Starter
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Here are some pics of dry fitting the extensions on the RA's and then 3 pass Tig welding them to over the bayonet. I know I'm going to catch some flack for these extensions not being beefy enough, but try to keep your comments to constructive criticism.
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Vochy: '06 F-150, Black Supercab Short box, 5.4L 4x4 XLT, 1" Daystar Leveling Kit, 275 70 R17 BFG A/T KO's
88' F-150 Black Short Box, 302 4x4, true dual flowmater 2in exaust, Mustang equal length headers, 31X10.50 R15 BFG A/T KO's, New Doors and Fenders installed, MAF conversion, Six Liter Tune up, Saginaw Power Steering Pump upgrade, P&P GT40 Heads, 3G Alt Upgrade, D44 SAS and 9" rear in-process.
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  Ford Bronco Forum > Bronco Discussions > Solid Axle Swaps

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