77 Dana44

[redfishtony]

OK I think I got lucky. After cleaning this axle up and getting the numbers off the tube it appears to be a 77 Standard with 3.50 ratio. My existing 9" is also a 3.50 ratio so I should be good to go. It does appear to have bigger u-joints so I assume the axle ends will be different also from the standard D44 short axles. The measurement on the drivers side is almost exactly the same as the D30 I removed (within 1/4") so all I should have to do is move the wedges just a bit. On the passenger side the tube is 4"+- longer so I will shorten this side. It seems removing it from the housing would be better but will I be able to get it back in and straight? If I go the other way I will have to cut the wedges and C off and but the tube should stay straight. Maybe the better way afterall. Sorry for the lengthy post. I have attached some pictures before and will try to post my progress. Wish me luck. ;D

 

[thegreatjustino]

Whether you remove the tube from the pumpkin or the knuckle mount from the end in order to shorten, you're still going to have the same concern about getting the rotation correct for caster.

 

[sykanr0ng]

With the inner C off on one side and wedges off you are more than half way to what you need to do a cut and turn, which solves both pinion angle problems and caster angle problems.

 

[redfishtony]

I shouldn't have a pinion angle issue should I because its a high pinion axle. The caster angle may be another story but I guess I will figure it out. Seems to be a very popular swap even having to shorten one side. One of my concerns is the axle/ujoint size. Will I be able to get a shorter axle with the bigger joints on it or can I have the existing axle cut and splined. Not sure if that can be done.

 

[thegreatjustino]

Seems to be a very popular swap even having to shorten one side.

Very few people shorten and install a high pinion axle. A vast majority are installed by guys going full width.

 

[SteveL]

If you narrow the passenger side to EB width you have plenty of axle shaft options. Pretty sure you can run a stock eb axleshaft. The vendors used to sell the beefier fw axle shaft cut down to eb length but now that chromoly axles have gotten cheaper that's the more common upgrade.

 

[mrdrnac]

Check out this thread for how to:

https://classicbroncos.com/forums/showthread.php?t=289710

I just finished doing my cut down 77 Dana 44HP also! Took 6" off the passenger side and used Chrome Moly WH axles (these use the bigger U-joints). Stock Bronco length works on the passenger side and you can use the stock Bronco length on the driver side as well, but it is about 1/2" shorter than the F150 one. WH also carries the F150 Chrome Moly axles. They sold me a set that was the Bronco length on the passenger side and the F150 length for the driver side. I just felt better about having the exact right length axle in the driver's side.

 

[redfishtony]

Mrdrnac, Nice looking front axle for sure. A couple of questions for you. It looks like you modified the steering arm and control arm or are those aftermarket arms. Also I notice a dent in you oil pan. Is this for clearance or from fun? Ive read that the high pinions can enter-fear with the oil pans unless you have a lift. What kind of coating did you use, paint, POR or some other product. It looks really good. Sorry for all the questions. Thanks, TW

 

[mrdrnac]

I've got a 5.5" lift on my Bronco so it has a drop track bar bracket on it and a dropped pitman arm and WH's adjustable track bar and adjustable drag links. They keep everything centered.The oil pan did clearance itself on my old Dana 30 axle, my engine is a 351 Cleveland, so your results may vary. But you do need at least a 3.5" lift to use the High Pinion axle, I believe. I should not have any clearance issues now! My axle just got finished and I just used spray paint on it as mine is made for use and not show.

 

[redfishtony]

Mrdrnac, Thanks for the information. I am running a 351W so I’ll have to keep an eye out for issues. Mine will be for driving also so I like the rattle can paint also. I’ve found the rustolium premium seems to hold up great. TW

 

[SteveL]

351w with 3.5 suspension usually has pan issue with the hp 44. Milodon makes a 351w 4x4 pan that has a notch cut out for clearance. Nice pan but its pricey and the pickup tube is extra.