Ford 1 ton brakes on Dana 44

Fords big, twin piston, 3/4 ton and 1 ton front calipers and mounts will fit a Dana44 solid axle with 17" rims and 2002 Dodge Ram 1500 front rotor. The rotors have to be machined down to the proper diameter.

Don't be confused by my pictures cause I actually did this on my Hybrid 609. The hubs are Dana 60 hubs reworked for 5 on 5 1/2 but I have helped a guy at Pirate do this to his solid D44.

The rotor is the key. The stock D44 rotor has a diameter that is too small, the stock 8 lug D60 rotor hole is way to big to think about fitting properly to try and convert it to 5 on 5 1/2. I found the 2002 Dodge Ram 1500 rotor 5 on 5 1/2 to work after being machined down to 12.6" diameter. Compare rotor sizes below:

Ford Dana 44 rotor:
Diameter:11.72"
Height:2.54"
Thickness When New:1.03"
Discard Thickness:.96"

Ford D60 Rotor
Diameter:12.56"
Height:3.23"
Thickness When New:1.25"
Discard Thickness:1.18"

2002 Dodge Ram 1500 Rotor
Diameter : 13.23"
Height : 2.66"
Thickness New : 1.1"

Here's the F250/350, 8 lug rotor sitting on a 5 on 5 1/2 rim:


You get a little bit bigger diameter rotor over the D44 for more leverage and better stopping power. The biggest increase in braking comes from the larger, twin piston calipers and larger pads. There is more surface contact between the pad and rotor.