D44 Big brake upgrade question - Ford Bronco Forum
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post #1 of 36 (permalink) Old 09-24-2016, 10:17 PM Thread Starter
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D44 Big brake upgrade question

Hi all,

So i picked up a choice "new" D44 from a 78 Bronco the other day.







So here's my question. I chose the 44 because it is litterally hundereds of pounds lighter than a 60. But I've read about the 8 lug swap that can be done to a D44 TTB. Do the same components swap over to a solid axle D44?
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post #2 of 36 (permalink) Old 09-25-2016, 08:18 AM
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I'm no expert, because I haven't tried it yet, but....

If you have a TTB and want it 8 lug, you have to use chevy spindles out (depending on year of TTB).

If you have a solid axle Dana 44 and want 8 lugs, you can use knuckles out from either a 78-9 F250 D44, or chevy knuckles out from whatever vehicles they used 8 lugs in, like K20s.

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post #3 of 36 (permalink) Old 09-25-2016, 08:23 AM
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Also interested in this.
The most I have seen done is swapping to a t-bird caliper as it has a larger piston. Seems the best results come from switching over to hydroboost, even with stock everything else lots of people are then being able to look up a 36 or 37" tire. I have not run either personally, but will be going the stock brakes with hydro boost route.


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post #4 of 36 (permalink) Old 09-25-2016, 08:45 AM
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You can do an 8 lug swap using components from a heavy duty Dana 44. I got all the stuff to do mine but never got around to it. This included the rotors and hubs as well as the spindles. you can use the knuckles from your 5 lug. I never purchased the calipers for it but brake components themselves are much larger as well.
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post #5 of 36 (permalink) Old 09-25-2016, 09:16 PM Thread Starter
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You can use the same knuckles? That's cool. So it's just different spindles? Same axles? I've heard that the F250 D44 is wider though. Is that not true?
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post #6 of 36 (permalink) Old 09-25-2016, 09:23 PM
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I don't know what the caveat is, but there's something about the f250 that isn't 100%, i think.
Something about the u-joints binding, maybe?

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post #7 of 36 (permalink) Old 09-25-2016, 09:44 PM
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Is it that the axle shafts on the D44 F250 are different lengths than a standard 5 lug F150/bronco axle? shouldn't matter if you're only using the spindles from one. You might have to get the 'stub shafts' from that axle so they match up internally to the spindles.

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post #8 of 36 (permalink) Old 09-25-2016, 10:24 PM Thread Starter
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I've heard that the stub shafts from a chevy are also needed for a swap to 8 lugs on a TTB.
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post #9 of 36 (permalink) Old 09-26-2016, 08:28 AM
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Can't speak to the interchangeability of the 8 lug TTB parts on a solid axle..someone may very well have done it.

I believe the 8 and 5 lug axles are the same dimension, so shafts should be the same.
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post #10 of 36 (permalink) Old 09-26-2016, 02:19 PM
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wait, i re-read...i'm not sure what you're trying to do.

are you trying to get 8-lug axles for the TTB if possible and not use the solid axle you bought? or are you trying to see what is needed to convert your "new" solid axle to 8-lug?

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post #11 of 36 (permalink) Old 09-26-2016, 02:37 PM Thread Starter
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Sorry. Probably very confusing.

I'm trying to find out two Things:

Are the brakes bigger on an 8 lug D44 from an F250?

What do I need to find so that I can do the 8 lug swap to the solid axle 44 I have?

Sorry, I'm looking back and I realize I wasn't clear.
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post #12 of 36 (permalink) Old 09-26-2016, 02:38 PM
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I thought he was trying to convert the new solid axle to an 8 lug and wanted to know what specific parts he could use.
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post #13 of 36 (permalink) Old 09-26-2016, 03:51 PM
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Quote:
Originally Posted by RacersJunkyard View Post
Sorry. Probably very confusing.

I'm trying to find out two Things:

Are the brakes bigger on an 8 lug D44 from an F250?

What do I need to find so that I can do the 8 lug swap to the solid axle 44 I have?

Sorry, I'm looking back and I realize I wasn't clear.
yes, the brakes are bigger.

You have a couple choices, you can go my way and use knuckle out K20 stuff, which uses 12.5" rotors and single piston caliper. 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.

What rear axle are you using?

You can also use Dodge outer, but I only ran across 1 person that did that, no issue with Dodge stuff I just think the ford or chevy stuff is much easier to come by.

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post #14 of 36 (permalink) Old 09-26-2016, 03:58 PM Thread Starter
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I'm planning on using a sterling 10.25 with a disc brake conversion in the rear. The general vision of this truck is an upgrade to a 3/4 ton equipment so that I can tow reliably over long distances. I'm currently getting my E4OD rebuilt along with a rebuilt 4.9 straight six. Reliability in the field is the name of the game.
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post #15 of 36 (permalink) Old 09-26-2016, 03:59 PM Thread Starter
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Quote:
Originally Posted by jermil01 View Post
I thought he was trying to convert the new solid axle to an 8 lug and wanted to know what specific parts he could use.
Yes that's exactly what I'm trying to figure out.
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post #16 of 36 (permalink) Old 09-26-2016, 04:08 PM Thread Starter
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Quote:
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.
So with a 250 upgrade will I need different outer stub shafts you think?
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post #17 of 36 (permalink) Old 09-26-2016, 05:04 PM Thread Starter
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Also I just found these spindles on bronco graveyard.

http://shop.broncograveyard.com/mobile/Spindle-Dana-44-1978-79-3_4-Ton/productinfo/21706/


Seems like they would bolt up to the stock d44 knuckles. Then I'd just need to bolt the hub and rotor on. The only piece I seem to be missing is how to attach the double piston caliper.
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post #18 of 36 (permalink) Old 09-27-2016, 08:27 AM
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For reference. Here are the 8 lug spindles in comparison to the 5 lug stuff. bolt holes for mounting to the knuckle are exactly the same.

8 lug spindle on the left



8 lug hub compared to 5 lug, 8 lug on the left



8 lug measure about 3.5 inches across.


5 lug 3.25



8 lug knuckle and caliper bracket



8 lug caliper

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post #19 of 36 (permalink) Old 09-28-2016, 03:39 PM
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Quote:
Originally Posted by jermil01 View Post
You can do an 8 lug swap using components from a heavy duty Dana 44. I got all the stuff to do mine but never got around to it. This included the rotors and hubs as well as the spindles. you can use the knuckles from your 5 lug. I never purchased the calipers for it but brake components themselves are much larger as well.
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. In fact if going to the 8 lug, the rotor is a larger diameter and may not work with the 5 lug caliper and the offset of the hub might be different (to the outside more I think by 1/2") causing alignment issues trying to run the small brakes on the big hubs. Keep it simple and get everything outer from the F-250.
You will need the knuckle, outer stub shaft, spindle, hub, caliper bracket, calipers and rotor. Just the lockouts are interchangeable.
It's all covered in this from Mr. N, scroll down to Ford 5 lug vs. 8 lug knuckles.
Mr.N's Dana 44 Flatop Knuckles

Also consider if going to the dual piston calipers you will then need to upgrade your master cylinder to increase fluid volume and especially if going disc in the rear as well. I picked up a larger master cylinder that fits a mid 90's Lighting and is a direct bolt-in, it has a larger bore size, I can't remember the specifics right now though.
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post #20 of 36 (permalink) Old 10-01-2016, 11:01 PM Thread Starter
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Okay, well that seems easy enough. Now I just need to find some knuckles from a 78.
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