D44 Big brake upgrade question - Page 2 - Ford Bronco Forum
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post #21 of 36 (permalink) Old 10-02-2016, 09:42 AM
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The super 44 was essentially the same axle, just 1 ton outers. One thing to watch is the pilot for the spindles are different diameters where the spindle inserts to the knuckle. Using the smaller pilot in the bigger knuckle is not a good idea, they will bolt up but this puts the shear load on the bolts ( bad idea and could cause catastrophic failure ).
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post #22 of 36 (permalink) Old 10-05-2016, 04:13 PM Thread Starter
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Quote:
Originally Posted by 445 FE Bronco View Post
The super 44 was essentially the same axle, just 1 ton outers. One thing to watch is the pilot for the spindles are different diameters where the spindle inserts to the knuckle. Using the smaller pilot in the bigger knuckle is not a good idea, they will bolt up but this puts the shear load on the bolts ( bad idea and could cause catastrophic failure ).
Are you talking about the where the ball joints from the knuckle attach to the axle assembly or where the spindle attaches to the knuckle? Sorry i've never heard of the 'pilot' before.

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post #23 of 36 (permalink) Old 10-05-2016, 05:40 PM
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Originally Posted by RacersJunkyard View Post
Are you talking about the where the ball joints from the knuckle attach to the axle assembly or where the spindle attaches to the knuckle? Sorry i've never heard of the 'pilot' before.
He means where the spindle mounts to the knuckle, it fits snug into the knuckle. If swapping around different spindles with different knuckles make sure the spindle fits tight into the knuckle. Usually it takes a spindle socket on a slide hammer to properly remove the spindle because of the tight fit and rust. There is a few different ways to remove the spindle though. I've gotten lucky on some at the junkyard and they come of with just a little persuasion.

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post #24 of 36 (permalink) Old 10-05-2016, 06:01 PM Thread Starter
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Okay, that makes sense. In the past I've been lucky with removing the spindle using a dead blow hammer and some careful taps.

Also, maybe I'm bad at using the internet but I can't for the life of me find any knuckles from a 250 D44.

Anyone know where I can find them?
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post #25 of 36 (permalink) Old 10-05-2016, 06:16 PM
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I have only ever seen them on Craigslist and usually the entire axle only and they are becoming very few and far between, I stalk Craigslist daily for Dana 44 stuff and very very rarely see the heavy duty 44's from 78/79 F-250's, maybe once or twice a year in the Phoenix and northern Arizona listings. Someone in Prescott near me just had all the outers except the knuckles on Craigslist. The knuckles are harder to find, they are desirable because they are flat top for high steer. I would never run high steer on a heavy rig like our trucks though.
A guy down the street from me has a '79 F-250 with the heavy 44 under it just sitting by the side of his house rotting away for the three years I have lived in the neighborhood. I keep meaning to stop in and ask what he wants for the truck.

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post #26 of 36 (permalink) Old 10-05-2016, 10:00 PM
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There's a guy in the fs section selling knuckles from a 78/79 axle. Is that what you're talking about?

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post #27 of 36 (permalink) Old 10-05-2016, 10:03 PM
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post #28 of 36 (permalink) Old 10-06-2016, 07:17 PM Thread Starter
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good looking out! That could be the 2nd time you've found good parts for my truck!

I inquired about the knuckles, we'll see what he says.
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post #29 of 36 (permalink) Old 10-07-2016, 03:13 PM
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Originally Posted by Shadofax View Post
Or go ford F250 with dual piston caliper, which won't fit 15" wheels as I recall. Not a biggy these days, I think it's great to get new 17" wheels anyway.
.
With the Ford 78/79 F250 D44 8 lug outers you can run 15" rims with 2.75" Back spacing.

Quote:
Originally Posted by jermil01 View Post
8 lug knuckle and caliper bracket
That's a 5 lug D44 caliper bracket.

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Originally Posted by Alwaysdirty View Post
He will need all the outers from a 78/79 F-250,you cannot use the knuckles from the 5 lug if you wish to use the dual piston calipers, the caliper bracket will interfere with the knuckle.
That's incorrect 78/79 F250 d44 interchange with a 78/79 1/2 ton.
I've used the 1/2 ton knuckles with the 8 lug outers and everything bolted up. There are numerous write ups on the Forum confirming this.

The only time there will be a difference is if you use a 76-77 D44 8 lug outers with the external lock out hubs you'll have to change the stub shaft to make it compatible.

F250's
78/79 stubs are 9.72" / 76-77 stubs are 10.66"

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post #30 of 36 (permalink) Old 10-07-2016, 11:44 PM Thread Starter
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Quote:
Originally Posted by badass1tonf100 View Post


I've used the 1/2 ton knuckles with the 8 lug outers and everything bolted up. There are numerous write ups on the Forum confirming this.

The only time there will be a difference is if you use a 76-77 D44 8 lug outers with the external lock out hubs you'll have to change the stub shaft to make it compatible.

F250's
78/79 stubs are 9.72" / 76-77 stubs are 10.66"
So three questions then:

1. When you used the 1/2 ton outers did that allow you to use the 3/4 ton two pot caliper?

2. Would you mind directing me to one of those threads? The only D44 5 to 8 lug conversion threads I've found have been for the TTB.

3. With 8 lug stuff from the spindle out will that make the front track wider?
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post #31 of 36 (permalink) Old 10-08-2016, 08:43 AM
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Originally Posted by RacersJunkyard View Post
So three questions then:

1. When you used the 1/2 ton outers did that allow you to use the 3/4 ton two pot caliper?

yes I was able to run the dual piston calipers.

2. Would you mind directing me to one of those threads? The only D44 5 to 8 lug conversion threads I've found have been for the TTB.
I'll look for them and post up. Look for Bronkzilla, Stressed, Squatty D, Red wagon those are other members whom done this.
3. With 8 lug stuff from the spindle out will that make the front track wider?
No will be same track width as 1/2 ton unless your running the 76-77 outer which have external lock outs

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post #32 of 36 (permalink) Old 10-15-2016, 12:20 AM
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Quote:
Originally Posted by badass1tonf100 View Post


That's incorrect 78/79 F250 d44 interchange with a 78/79 1/2 ton.
I've used the 1/2 ton knuckles with the 8 lug outers and everything bolted up. There are numerous write ups on the Forum confirming this.

The only time there will be a difference is if you use a 76-77 D44 8 lug outers with the external lock out hubs you'll have to change the stub shaft to make it compatible.

F250's
78/79 stubs are 9.72" / 76-77 stubs are 10.66"
Apologies, I was remembering it backwards. Can't use half ton brakes on the flat top knuckles. The flat top knuckles are not notched for the smaller brakes.
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post #33 of 36 (permalink) Old 10-25-2016, 10:52 AM Thread Starter
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So if all that's true, and all I'm after is an 8 lug swap with larger brakes I will only need:

1/2 ton knuckle
3/4 ton spindle
8 lug hub
3/4 ton brake caliper/rotor
3/4 ton brake caliper hanger
3/4 ton outer stub shaft
Bearings, locking hubs, races etc...

Yes?
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post #34 of 36 (permalink) Old 10-27-2016, 03:40 PM Thread Starter
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So, after some digging I found this kit.

https://lugnut4x4.com/product/dana-6...onversion-kit/

It's an 8 lug brake kit for ford 8 lug Dana 44s. It uses 3/4 ton chevy parts and looks like all I'd need after this upgrade would be to get new spindles, hubs and stubs. Seems like the price is right too.

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post #35 of 36 (permalink) Old 10-27-2016, 04:00 PM
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Another option, potentially. Yes I know its expensive but this is race quality stuff that should be better then any factory parts, even the 8 lug stuff.
Flight industries fabricated knuckles and brakes - GoFastBroncos.com


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post #36 of 36 (permalink) Old 10-27-2016, 05:23 PM Thread Starter
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Just spoke with the owner of lugnut and he said that he's done the 1/2 ton 8 lug swap using his components before. So turns out it can be done. I'll probably be ordering mine soon.
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