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I will use this thread as my TODO list as well, so pardon the 800 lines of things to do.
Details:
HP Dana 44 from a '78 F150:
CAGE extended radius arms
4.88 gears
Superflex 5.5" lift springs
Thunderbird calipers
Center drop brake lines
CAGE 14" travel shocks
Parts Acquisition:
'78 F150 D44HP - Purchased
'78 F150 Coil Buckets and Retainers - Purchased
'78 F150 Coil Cups and Retainers - Purchased
Inner Axle Seals - Purchased
Ball Joints - Purchased
New Diff Cover Bolts - Purchased
Pinion Nut and Washer - Purchased
Spicer Axle Shaft Ujoints - Purchased
Wheel Bearings Races and Seals - Purchased
Spindle bearings and seals - Purchased
Diff cover gasket - Purchased
D44 Reverse Rotation 4.88 gears - Purchased from muddinBronc
D44 Gear Install Kit - Purchased from muddinBronc
D44 Open Carrier for 3.93 and up ratios - Purchased from william_ace
8.8 4.88 gears - Purchased from ericautopart
8.8 Gear Install Kit - Purchased from ericautopart
F250 Upper Shock Mounts - Purchased
CAGE radius arms - Purchased from GearHead
Superflex 6" Coils - Purchased
One brake rotor (Already had one new one) - Purchased
Brake pads - Purchased
New caliper mounting hardware - Purchased
'79 Thunderbird calipers - Purchased
Thunderbird caliper banjo bolts - Purchased
Brake hose/line - Purchased
F350 Steering - Purchased
Superlift Trac bar - Purchased from broncomania
Stock pitman arm - Purchased
Gear install Front - Purchased
Gear install Rear - Purchased
New Front Shocks - Purchased
Miscellaneous Steel - Purchased
Miscellaneous Hardware - Purchased
To Do:
Disassemble axle - Done
Clean and paint axle - Done
Clean and paint caliper mounts - Done
Clean and paint knuckles - Done
Clean and paint coil buckets - Done
Clean and paint spindles - Done
Press out axle shaft u-joints - Done
Clean and paint axle shafts - Done
Press in new axle shaft u-joints - Done
Clean and paint coil cups - Done
Replace ball joints - Done
Replace axle shaft inner seals - Done
Have gears installed in front axle - Done
Have gears installed in rear axle - Done
Install knuckles - Done
Install caliper mount - Done
Install axle shafts - Done
Press out old spindle bearings - Done
Install new spindle bearings - Done
Install spindle - Done
Clean and paint radius arms - Done
Remove hubs, wheel studs, lockouts from TTB - Done
Install wheel bearings, seals, hubs, rotors - Done
Install radius arms, and coil caps - Done
Install coils - Done
Bend/install axle center drop brake line - Done
Remove TTB components - Done
Grind off TTB coil buckets - Done
Grind off TTB crossmember - Done
Bend power steering lines up 90* - Done
Re-install power steering cooler - Done
Measure and install '78 coil buckets - Done
Measure drill, and bolt up radius arm mounts - Done
Build tranny x-member - Done
Install tranny x-member - Done
Build upper trac-bar mount - Done
Install upper trac-bar mount - Done
Install trac-bar - Done
Install tie rod and drag link - Done
Install upper shock mounts - Done
Install shocks - Done
Measure and install bump stops - Not Done
Install wheels and driveshaft - Done
Add fluid - Done
Install brakes - Done
Bleed brakes - Done
Bleed power steering - Done
Professional alignment - Not Done
Wheel the piss out of the new axle - Not Done
Pictures of it as it sat:
Yanked it out:
Teardown and Cleanup:
ICK! I was hoping I could get away with regearing later, but looks like I'll have to replace the carrier bearings anyways.
Questions:
In some of the above pics you can see the stock tracbar and mount, is the frame so different that this is unusable for the bronco with a lift? I'd assume so as it's not adjustable.
I don't figure there is any way I can really get away with regearing later after you've seen the axle tubes and diff housing eh?
The gears threw a wrench in my budget, is it a big change to run stock radius arms until some cage or duff one's fit the budget? Will the flex SEVERELY suffer without them?
gear recommendations, for 35" tires, possibly up to 37"s maximum (I won't be locking the axle) I was thinking 4.88s
More to come, I'm very tired so I'll clean this post up some tomorrow.
Please feel free to give me LOTS of input
-Alex
Details:
HP Dana 44 from a '78 F150:
CAGE extended radius arms
4.88 gears
Superflex 5.5" lift springs
Thunderbird calipers
Center drop brake lines
CAGE 14" travel shocks
Parts Acquisition:
'78 F150 D44HP - Purchased
'78 F150 Coil Buckets and Retainers - Purchased
'78 F150 Coil Cups and Retainers - Purchased
Inner Axle Seals - Purchased
Ball Joints - Purchased
New Diff Cover Bolts - Purchased
Pinion Nut and Washer - Purchased
Spicer Axle Shaft Ujoints - Purchased
Wheel Bearings Races and Seals - Purchased
Spindle bearings and seals - Purchased
Diff cover gasket - Purchased
D44 Reverse Rotation 4.88 gears - Purchased from muddinBronc
D44 Gear Install Kit - Purchased from muddinBronc
D44 Open Carrier for 3.93 and up ratios - Purchased from william_ace
8.8 4.88 gears - Purchased from ericautopart
8.8 Gear Install Kit - Purchased from ericautopart
F250 Upper Shock Mounts - Purchased
CAGE radius arms - Purchased from GearHead
Superflex 6" Coils - Purchased
One brake rotor (Already had one new one) - Purchased
Brake pads - Purchased
New caliper mounting hardware - Purchased
'79 Thunderbird calipers - Purchased
Thunderbird caliper banjo bolts - Purchased
Brake hose/line - Purchased
F350 Steering - Purchased
Superlift Trac bar - Purchased from broncomania
Stock pitman arm - Purchased
Gear install Front - Purchased
Gear install Rear - Purchased
New Front Shocks - Purchased
Miscellaneous Steel - Purchased
Miscellaneous Hardware - Purchased
To Do:
Disassemble axle - Done
Clean and paint axle - Done
Clean and paint caliper mounts - Done
Clean and paint knuckles - Done
Clean and paint coil buckets - Done
Clean and paint spindles - Done
Press out axle shaft u-joints - Done
Clean and paint axle shafts - Done
Press in new axle shaft u-joints - Done
Clean and paint coil cups - Done
Replace ball joints - Done
Replace axle shaft inner seals - Done
Have gears installed in front axle - Done
Have gears installed in rear axle - Done
Install knuckles - Done
Install caliper mount - Done
Install axle shafts - Done
Press out old spindle bearings - Done
Install new spindle bearings - Done
Install spindle - Done
Clean and paint radius arms - Done
Remove hubs, wheel studs, lockouts from TTB - Done
Install wheel bearings, seals, hubs, rotors - Done
Install radius arms, and coil caps - Done
Install coils - Done
Bend/install axle center drop brake line - Done
Remove TTB components - Done
Grind off TTB coil buckets - Done
Grind off TTB crossmember - Done
Bend power steering lines up 90* - Done
Re-install power steering cooler - Done
Measure and install '78 coil buckets - Done
Measure drill, and bolt up radius arm mounts - Done
Build tranny x-member - Done
Install tranny x-member - Done
Build upper trac-bar mount - Done
Install upper trac-bar mount - Done
Install trac-bar - Done
Install tie rod and drag link - Done
Install upper shock mounts - Done
Install shocks - Done
Measure and install bump stops - Not Done
Install wheels and driveshaft - Done
Add fluid - Done
Install brakes - Done
Bleed brakes - Done
Bleed power steering - Done
Professional alignment - Not Done
Wheel the piss out of the new axle - Not Done
Pictures of it as it sat:













Yanked it out:


Teardown and Cleanup:






ICK! I was hoping I could get away with regearing later, but looks like I'll have to replace the carrier bearings anyways.






Questions:
In some of the above pics you can see the stock tracbar and mount, is the frame so different that this is unusable for the bronco with a lift? I'd assume so as it's not adjustable.
I don't figure there is any way I can really get away with regearing later after you've seen the axle tubes and diff housing eh?
The gears threw a wrench in my budget, is it a big change to run stock radius arms until some cage or duff one's fit the budget? Will the flex SEVERELY suffer without them?
gear recommendations, for 35" tires, possibly up to 37"s maximum (I won't be locking the axle) I was thinking 4.88s
More to come, I'm very tired so I'll clean this post up some tomorrow.
Please feel free to give me LOTS of input
-Alex