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Ford 1 ton brakes on Dana 44

7007 Views 3 Replies 2 Participants Last post by  Midnyte
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:
Thickness When New:1.03"
Discard Thickness:.96"

Ford D60 Rotor
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.
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The Dodge rotor is machined-out for 9/16" lugs/studs. You will need to upgrade to 9/16" lugs or utilize spacers/sleeves on the lugs. You'll need to redrill the hub to fit 9/16" lugs. You don't want the rotor to have any slop on the hub so at least use the spacers and make sure the hole that slips over the hub is a tight fit. This is what I came-up with to make the 1/2 lugs work:

I used 1990 F250 caliper mounts and calipers.

These are not 1990 but very similar. I don't think much changes but how the calipers mount in the brackets.

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Completed project with 17 rims:

Completed Dana 44 (slightly different calipers and mounts):

I did not need a larger than stock master cylinder with these twin piston calipers and rear drum brakes. I did need to go with a 1 3/8" F350 master and got the matching booster when I swapped-in a Sterling rear with disk brakes. I don't know if this will work on the TTB.

My Cost:
Ultra premium Napa rotors $130
Machining $120
Used caliper mounts and Calipers maybe $100
Rebuilt calipers $112
Premium Pads $60

There a less expensive parts and you might do a little better at a machine shop than I did.
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Hmmm, I may have to look more into this. My stock brakes don't want to stop my 37's as well as I'd like them to. Good write-up :thumbup
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