Dustin
03-04-2003, 03:13 PM
copyed from dogonmut from that *othersite*
Sterling 10.25 / Dana 44 8 lug conversion (1978 model)
Much like my front-end swap, there are a million ways to skin a cat and this is only one of them. It’s what made sense to me for the wheelin’ I do and the way I run my rig. It’s also part of the larger, over all plan I have for the rig. This is merely a cost break down to give you an idea of what it took me as well as the time I spent working on the set up.
Both of these swaps are really strait forward. The 8-lug conversion is just pulling your spindles off, replacing the caliper bracket, and doing a break job…with bigger parts of course.
As for the 10.25, it to is about as simple as it gets. The project does require welding but if you are really thinking of doing this you probably have the means.
I hope this helps someone considering either or both swaps.
Good luck,
-Scott
- Sterling 10.25 Swap -
$375.00 Complete 95 Sterling 10.25 salvage axle (Less then 40,000 miles on the donor truck. Awesome! )
$265.00 4.56:1 gears (US Gear)
$150.00 Over haul kit (not a master install)
$35.00 Randy’s Ring and Pinion Super Shim Carrier shim kit
$45.00 1330 pinion yoke and strap kit (Spicer)
$20.00 1330 U joint (Spicer)
$350.00 Lock Right (Power Tracks)
$75.00 Pro done drive line work. (removed 1.75”)
$32.00 16 lug nuts (OEM)
$45.00 2 gallons of gear oil, RTV, Grease, etc.
$52.00 5/8 U bolts (Valley Spring)
$42.00 78 F250 spindles (2) (salvage)
$1487.00 Total
*I did not rebuild the breaks. The ones it came with were in perfect shape. If I had, it would have cost about $75.00 more.
- 8 lug dual piston caliper Dana 44 front end conversion -
$60.00 1978 F250 hubs (salvage)
$70.00 New rotors (2) (Auto Zone)
$20.00 1978 outer caliper (2) (salvage)
$90.00 remanufactured caliper (2)(NAPA)
$30.00 break hardware (Auto Zone)
$45.00 pads (Checker)
$40.00 1978 dual piston caliper bracket (2) (salvage)
$45.00 outer wheel bearing (2)(Auto Zone)
$32.00 inner wheel bearings (2) (Auto Zone)
$6.00 inner wheel bearing seals (2) (Auto Zone)
$32.00 16 lug bolts(NAPA)
$24.00 16 lug nuts (NAPA)
$84.00 1994 F250 Master Cylinder (Auto Zone)
$7.00 grease, break fluid, etc.
$585.00 total
Tools used:
·Pneumatic – ½” impact gun, 3/8 ratchet
·Electric – 4.5” angle grinder
·Fab - MIG welder
·Specitiality – the usual stuff to set up gears, Dana 44 hub tool
·Shop – 20 ton press, vice, hand tools (socket, wrenches, drivers, etc.), jacks (2), tall jack stands (2)
Times for 10.25 swap:
·6 hours to locate parts over a 4 month span
·2 hours to clean and prep parts
·4 hours to regear 10.25
·1 hour to remove 8.8 (2 people)
·1 hour fab work (cut off and reweld spring perches)
·2 hours install 10.25 under truck (2 people)
16 hours total
Times for 8 lug conversion:
·6 hours over 4 months to locate parts
·1 hour clean and prep salvage parts
·1 hour remove 5 lug set up, clean reused parts
·1 hour pack new bearings, press in new races and lugs
·2.5 hours install new parts and master cylinder
11.5 hours total
Rear end parts reused:
·Brake line
·Electrical wiring to wheel speed sensor
*I got lucky. My 10.25 came with E-brake cables and they were the correct length to tie into the same bracket that the 8.8 used.
5 lug parts reused:
·Warn hubs
·Banjo bolts
·Brake lines
·Cosmo alignment shims
·Knuckles
·Ball joints
*The last 3 obviously did not have to be removed to do the swap.
Check out my Super Ford page to see some limited pictures of the swap. I really need to take more pictures when I'm working on a project.
Sterling 10.25 / Dana 44 8 lug conversion (1978 model)
Much like my front-end swap, there are a million ways to skin a cat and this is only one of them. It’s what made sense to me for the wheelin’ I do and the way I run my rig. It’s also part of the larger, over all plan I have for the rig. This is merely a cost break down to give you an idea of what it took me as well as the time I spent working on the set up.
Both of these swaps are really strait forward. The 8-lug conversion is just pulling your spindles off, replacing the caliper bracket, and doing a break job…with bigger parts of course.
As for the 10.25, it to is about as simple as it gets. The project does require welding but if you are really thinking of doing this you probably have the means.
I hope this helps someone considering either or both swaps.
Good luck,
-Scott
- Sterling 10.25 Swap -
$375.00 Complete 95 Sterling 10.25 salvage axle (Less then 40,000 miles on the donor truck. Awesome! )
$265.00 4.56:1 gears (US Gear)
$150.00 Over haul kit (not a master install)
$35.00 Randy’s Ring and Pinion Super Shim Carrier shim kit
$45.00 1330 pinion yoke and strap kit (Spicer)
$20.00 1330 U joint (Spicer)
$350.00 Lock Right (Power Tracks)
$75.00 Pro done drive line work. (removed 1.75”)
$32.00 16 lug nuts (OEM)
$45.00 2 gallons of gear oil, RTV, Grease, etc.
$52.00 5/8 U bolts (Valley Spring)
$42.00 78 F250 spindles (2) (salvage)
$1487.00 Total
*I did not rebuild the breaks. The ones it came with were in perfect shape. If I had, it would have cost about $75.00 more.
- 8 lug dual piston caliper Dana 44 front end conversion -
$60.00 1978 F250 hubs (salvage)
$70.00 New rotors (2) (Auto Zone)
$20.00 1978 outer caliper (2) (salvage)
$90.00 remanufactured caliper (2)(NAPA)
$30.00 break hardware (Auto Zone)
$45.00 pads (Checker)
$40.00 1978 dual piston caliper bracket (2) (salvage)
$45.00 outer wheel bearing (2)(Auto Zone)
$32.00 inner wheel bearings (2) (Auto Zone)
$6.00 inner wheel bearing seals (2) (Auto Zone)
$32.00 16 lug bolts(NAPA)
$24.00 16 lug nuts (NAPA)
$84.00 1994 F250 Master Cylinder (Auto Zone)
$7.00 grease, break fluid, etc.
$585.00 total
Tools used:
·Pneumatic – ½” impact gun, 3/8 ratchet
·Electric – 4.5” angle grinder
·Fab - MIG welder
·Specitiality – the usual stuff to set up gears, Dana 44 hub tool
·Shop – 20 ton press, vice, hand tools (socket, wrenches, drivers, etc.), jacks (2), tall jack stands (2)
Times for 10.25 swap:
·6 hours to locate parts over a 4 month span
·2 hours to clean and prep parts
·4 hours to regear 10.25
·1 hour to remove 8.8 (2 people)
·1 hour fab work (cut off and reweld spring perches)
·2 hours install 10.25 under truck (2 people)
16 hours total
Times for 8 lug conversion:
·6 hours over 4 months to locate parts
·1 hour clean and prep salvage parts
·1 hour remove 5 lug set up, clean reused parts
·1 hour pack new bearings, press in new races and lugs
·2.5 hours install new parts and master cylinder
11.5 hours total
Rear end parts reused:
·Brake line
·Electrical wiring to wheel speed sensor
*I got lucky. My 10.25 came with E-brake cables and they were the correct length to tie into the same bracket that the 8.8 used.
5 lug parts reused:
·Warn hubs
·Banjo bolts
·Brake lines
·Cosmo alignment shims
·Knuckles
·Ball joints
*The last 3 obviously did not have to be removed to do the swap.
Check out my Super Ford page to see some limited pictures of the swap. I really need to take more pictures when I'm working on a project.