Planning a build….

[jeffncs]

Nothing too crazy but taking advice…

302 / c4 / Dana 20

Debating 33s vs 35s
Debating full width 1-tons

Will be driven by me offroad and around town. Sons may occasionally take it to HS.

Questions - seeking opinions

I have a couple different D44s and 9s around. Are 1-tons a dumb idea? I’m planning to lock the front and rear regardless.

I have a complete 3.5” lift kit ready to install. Do I need more BL to run 35s and retain articulation?

As I mentioned, I’m planning…. Looking to start ordering lockers and gears to build the diffs and don’t want to do it again.

 

[Yeller]

If you never want to worry about building again….. 1 tons and never look back. The parts cost difference is negligible more other than you already have D44’s and 9’s.

Here’s my Dana 44 story, 35’s, 4.56’s and Detroit locker. Built the axle with 100% new Spicer parts. Broke at least one axle every outing. Broke enough that a notable axle manufacturer asked about me testing some new high zoot fancy shafts, this was 2000, so that stuff was being developed. Rebuilt the axle with all new parts and prototype axles. Went out made it about 15 minutes and the front just stopped pulling. Broke all 4 axle shafts, destroyed both ujoints, broke the ring and pinion and the locker. It never made a sound.

Built a Dana 60, it already had factory 4.56’s, added a Detroit, acquired some 35 spline outer shafts, prototypes from Yukon, and some drive flanges. 8 years later I replaced the factory inner axle shafts, the ujoint holes had stretched and you could see daylight around them, with an off the shelf set of Yukon chromoly ones, and installed a new set of joints. Fast forward to today. Haven’t touched it and still going strong. However it is due a set of axle seals, and will get a set of ujoints when apart, the second pair in 25 years and 3rd vehicle the assembly has been in. Insult to injury when built I spent 1/2 of what I spent building the D44 the last time.

 

[1969]

My vote is for 05+ Super Duty axles

https://irate4x4.com/threads/05-ford-super-duty-dana-60-axle-tech-info.4199/

 

[jeffncs]

Thanks guys. I appreciate the suggestions.