Ford Truck Club Forum

Ford Truck Club Forum (http://www.fordtruckclub.net/forum/index.php)
-   Garage Talk: Solid Axle Swaps (http://www.fordtruckclub.net/forum/forumdisplay.php?f=95)
-   -   Dana 44 - Operation Break Down - Completed (http://www.fordtruckclub.net/forum/showthread.php?t=2091)

nine5flareside December 30th, 2009 09:06 PM

Dana 44 - Operation Break Down - Completed
 
Well I have a 1995 F150 with the crappy IFS front end. I've decided to do the SAS. I bought a high pinion Dana 44 front axle out of a 79 Bronco. I have yet to actually look up the serial number to make sure. It's not really important. Below will be the entire disassembly of the axle, removing old paint and then repainting it. The rebuild will be another thread!

Just a little side note about this particular axle:

1978 and 1979 were identical.
What makes this axle different to 1977 and older is one important thing, the
78-79 axle have the radius arm wedges molded into the housing as one piece.

The previous years, 77 and older, the radius arm wedges were welded on after
the housing was casted. So what does this mean to you if you're buying a d44?

This axle is setup ONLY for radius arms. Leaf springs or a 4 link setup can't be
done with the 78-79 axle. Do your homework! Ask around if you are not sure.

12/16/09

Here is the axle when I picked it up... six hours of driving... trip sucked! Axle is heavy!

http://www.fordtruckclub.net/forum/p...pictureid=1377

5 x 5.5 Lug Pattern and Manual Locking Hubs:

http://www.fordtruckclub.net/forum/p...pictureid=1382

A Bit Rusty But Nothing Major (from the outside):

http://www.fordtruckclub.net/forum/p...pictureid=1380

Here is Some Misc Parts From The Axle:

http://www.fordtruckclub.net/forum/p...pictureid=1401

12/29/09

The Dana 44 Break Down Begins

First Project is to open The Differential Cover:

http://www.fordtruckclub.net/forum/p...pictureid=1473

The Tools I used Were My Craftsman 1/2 Ratchet w/ Extension, Socket and Gloves.

http://www.fordtruckclub.net/forum/p...pictureid=1476

To remove the diff cover I needed the 1/2 inch socket.
To remove the bearing cap bolts you will need a 3/4 inch:

http://www.fordtruckclub.net/forum/p...pictureid=1475

After Making Sure There Was No Oil Inside I started To Crack It Open (1/2 inch socket and 6 inch extension):

http://www.fordtruckclub.net/forum/p...pictureid=1477

A bit rusty, the oil was drained before I got it:

http://www.fordtruckclub.net/forum/p...pictureid=1478

Be Sure To Keep Everything In Order... trust me:

http://www.fordtruckclub.net/forum/p...pictureid=1479

All looks well so we are moving on. Now its time to remove the axle from the housing. First thing is to remove the hub:

http://www.fordtruckclub.net/forum/p...pictureid=1949

I had to remove 5 little bolts with an allen key, pretty simple so far:

http://www.fordtruckclub.net/forum/p...pictureid=1954

Remember, KEEP EVERYTHING TOGETHER:

http://www.fordtruckclub.net/forum/p...pictureid=1956

Next, give the hub cover some soft taps with a rubber mallet until it pops off:

http://www.fordtruckclub.net/forum/p...pictureid=1955

Here it is:

http://www.fordtruckclub.net/forum/p...pictureid=1958

Before we go on, lets remove the brake caliper before it gets in the way, first unscrew this:

http://www.fordtruckclub.net/forum/p...pictureid=1960

Now with a hammer and flat head just some taps will get this right out of the groove:

http://www.fordtruckclub.net/forum/p...pictureid=1962

Next some nice and easy shots on both sides with a hammer should pop the caliper right off:

http://www.fordtruckclub.net/forum/p...pictureid=1964

Piece of cake, lets rock n' roll:

http://www.fordtruckclub.net/forum/p...pictureid=1966

OK next is time to remove all the hubs guts so we can slide the rotor assembly off:

http://www.fordtruckclub.net/forum/p...pictureid=1959

There is a ring here sitting in a channel holding all this is.
Just pry it out gently with a thin nail or screwdriver.
If you look at the image two pics down its the ring on the right:

http://www.fordtruckclub.net/forum/p...pictureid=1967

Once you get that unscrewed pull it away very easy because there are some guts that may fall out:

http://www.fordtruckclub.net/forum/p...pictureid=1969

See... guts! (Theres the ring on the right):

http://www.fordtruckclub.net/forum/p...pictureid=1970

OK. Moving on, this next step was a little tricky. There is a clip that has to be removed.
This clip needs to be spread apart to be removed... I dont have the correct tool for it:

http://www.fordtruckclub.net/forum/p...pictureid=1971

Sorry about the blurry pic but you'll see the clip soon enough. Anyway, I found a pair of
needle nose pliers and decided to grind grooves into the tips so the clip would sink into:

http://www.fordtruckclub.net/forum/p...pictureid=1976

Now that my tool is ready, it's time to party! OK lets get back to work, on the clip:

http://www.fordtruckclub.net/forum/p...pictureid=1972

OK so we got that off... lets see what it was:

http://www.fordtruckclub.net/forum/p...pictureid=1975

In this next image, this gear was giving me a hard time so I drowned it in WD40 to get any
grit that may be stopping it from sliding right off. It's supposed to slide right off:

http://www.fordtruckclub.net/forum/p...pictureid=1977

Once that gear is out, this just falls right out:

http://www.fordtruckclub.net/forum/p...pictureid=1978

Next, gently pull this out with a thin flat head:

http://www.fordtruckclub.net/forum/p...pictureid=1980

Believe it or not, it's time to remove the rotor!

http://www.fordtruckclub.net/forum/p...pictureid=1981

All gone:

http://www.fordtruckclub.net/forum/p...pictureid=1982

We will take these bearings out and call it a day:

http://www.fordtruckclub.net/forum/p...pictureid=1983

12/30/09

Picking up where we left off

Next project is to finish taking this damn thing apart, we will start with the spindle, gently hammer bolts out:

http://www.fordtruckclub.net/forum/p...pictureid=1985

All but one are able to come out and that's fine, the knuckle will be in the way:

http://www.fordtruckclub.net/forum/p...pictureid=1986

My plan is to keep the spindle, but it needs to be banged off...
so to save the threads I used a 2x4 and hammer:

http://www.fordtruckclub.net/forum/p...pictureid=1987

That plan sucked:

http://www.fordtruckclub.net/forum/p...pictureid=1988

Well after splitting another 2x4 I said to hell with it and I banged it off:

http://www.fordtruckclub.net/forum/p...pictureid=1990

Yummy!

http://www.fordtruckclub.net/forum/p...pictureid=1991

Slide the axle out nice and easy:

http://www.fordtruckclub.net/forum/p...pictureid=1992

That's it for today but next time we will work on removing the knuckle:

http://www.fordtruckclub.net/forum/p...pictureid=1993

1/28/10

Just about done

Time to remove the knuckle, the castle nut just kept spinning because of the ball joint it
was bolted on to, so I decided to finally use my dremel! I was getting new nuts anyway:

http://www.fordtruckclub.net/forum/p...pictureid=2021

OK outsides cut off, now its time for the inside nut (surprisingly, this one came right off)
Just bang out the ball joints and the knuckle will fall right to the floor (watch your toes):

http://www.fordtruckclub.net/forum/p...pictureid=2022

OK time to remove the carrier!!!! This was a pain but two pry bars worked wonders:

http://www.fordtruckclub.net/forum/p...pictureid=1997

Be sure to losen the bearing cap bolts but do not remove them. When we pry the carrier out
we dont want it to fall, so by keeping the bearing caps on but loose, they will catch the carrier:

http://www.fordtruckclub.net/forum/p...pictureid=1995

Lets move on. Position the bars inside the housing in a way that DOES NOT damage the carrier:

http://www.fordtruckclub.net/forum/p...pictureid=1996

After some struggling and more struggling and a little more, the carrier will pop right out.
Once loose, remove the bearing cap bolts and then remove the bearing caps, nice and easy:

http://www.fordtruckclub.net/forum/p...pictureid=1998

Pull the carrier and ring gear out and place it in a safe place:

http://www.fordtruckclub.net/forum/p...pictureid=1999

Now it's time to remove the pinion gear:

http://www.fordtruckclub.net/forum/p...pictureid=2000

This nut was the biggest pain out of the entire project:

http://www.fordtruckclub.net/forum/p...pictureid=1973

I wasted no time, well about 2 days, time for the dremel again make sure to WEAR eye protection:

http://www.fordtruckclub.net/forum/p...pictureid=2004

OK that was fun...pinion gear dropped right to the floor! I guess I wont be re-using this:

http://www.fordtruckclub.net/forum/p...pictureid=2005

Well after all that rust earlier all over the ring gear and bearing caps I was a little worried,
but this thing is squeaky clean:

http://www.fordtruckclub.net/forum/p...pictureid=2007

2/4/10

Time to remove all its sin

Well, I started cleaning this in between days where I was stuck. Heres the progress:

http://www.fordtruckclub.net/forum/p...pictureid=2003

Just about all paint removed:

http://www.fordtruckclub.net/forum/p...pictureid=2009

Now it's time to paint this thing, first thing was to take care of any rust that I missed
and to seal it from future rust, then prime and paint with hi-temp paint:

http://www.fordtruckclub.net/forum/p...pictureid=2010

Just about done:

http://www.fordtruckclub.net/forum/p...pictureid=2012

TODAY 2.09.10 ITS ALL DONE FINALLY!

http://www.fordtruckclub.net/forum/p...pictureid=2013

And a close up:

http://www.fordtruckclub.net/forum/p...pictureid=2014

Side note... I didn't remove the drivers side knuckle, rotor, hub or anything. The drivers side was completely
broken down already by previous owner. This project is over. Next project will be the rebuild of this axle.

To be continued. :sick:

Agjake11 December 30th, 2009 10:20 PM

looks like a sweet build project. what wheel and tire setup are you gonna run?? more lift?

Old Blue December 30th, 2009 10:55 PM

what gear ratio is the solid axle??? are you gonna keep your original gears are do a upgrade front and rear?

nine5flareside December 31st, 2009 12:40 AM

Quote:

Originally Posted by Agjake11 (Post 23166)
looks like a sweet build project. what wheel and tire setup are you gonna run?? more lift?

Here is what I have already for the truck:

http://www.fordtruckclub.net/forum/p...&pictureid=640

37" TOYO open country M/T

Im thinking of a 10 inch lift because I have a set of 16" M/T classic rims with the beadlock ring that are size 16" and I want to put the same tire on but in 38" (for the open country 16" rim 35" or 38" are my options).

Agjake11 December 31st, 2009 12:44 AM

gonna be a big jump from how it looks now but should look awesome. i love those tires

nine5flareside December 31st, 2009 12:49 AM

:grinz:
Quote:

Originally Posted by Old Blue (Post 23169)
what gear ratio is the solid axle??? are you gonna keep your original gears are do a upgrade front and rear?

The axle has a 3.55 gear set in it now I believe. I am not keeping it, I am going to upgrade to 4.56 gears. Not sure what brand yet.

Old Blue December 31st, 2009 01:03 AM

Congratulations on the beginning of loosing your sas virginity

ASwaff400 December 31st, 2009 08:33 AM

cant wait to see the end result! should look bad ass!

JSoko December 31st, 2009 08:46 AM

Damn Nine5, I hope that aint the bed of your '95

I know you cant wait to get it all together, work smart

LOL you seem to be a fan of long extensions

nine5flareside December 31st, 2009 10:55 AM

Quote:

Originally Posted by jsoko (Post 23194)
Damn Nine5, I hope that aint the bed of your '95

It is! One of the last things I plan on doing is removing the bed. Welding a plate of steel behind it to strengthen the back wall after I bang out some of the dents. Then rhinoline it or maybe do the duplicolor bed liner myself.

Quote:

Originally Posted by jsoko (Post 23194)
LOL you seem to be a fan of long extensions

Yes I am! Like you said:

Quote:

Originally Posted by jsoko (Post 23194)
work smart



All times are GMT -4. The time now is 08:28 PM.



FordTruckClub.net is not authorized, endorsed or affiliated with the Ford Motor Company
or any of their subsidiaries. FordŽ is a registered trademark of the Ford Motor Company


Powered by vBulletin® Version 3.8.6 Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.