Winter Front End Project

[Bartonatl]

I figured since it's cold outside, now would be a good time to shut down the bronco for a few needed repairs. 1) new gears in front because I changed the rear..and 2) rebuild Dana 20 T/C......So my questions are as follows.

1) I put 4.11 gears in the rear, so what can I put in the front Dana 44 to match the rear?
2) Since I have the front apart, what else should I do? Please don't say disc brake conversion, I'm on a budjet. (like spindle bearings, C bushings, etc.)
3) Moving on to the T/C rebuild, is there a good instructional video on-line? I looked and could not find one. I did find good threads with good information but not a step by step video of a tear down / rebuild. The parts in my T/C seem fine so I think I'm just looking at replacing bearings and seals.

Thanks for your input.

Russell

 

[kyle]

1. I think the front gear ratio options is going to 4.09 or 4.10.

2. Outer and Inner wheel bearings, and ball joints.

 

[Rustytruck]

For the front gears the cheapest way is to get a set of thick cut gears so you dont have to replace the carrier.
If junk yard shopping I found this on line.
'93-'97 Isuzu Rodeo's had Dana 44's and came with thick cut 4.11's from the factory. Pull the gears and install on your carrier.

On my Bronco I used thick cut gears with a trutrac in the front since the trutrac was origionally for a set of 3.50 gears. I bought my gears from Reider racing but they are also abvailable from our vendors above.

 

[Bartonatl]

I saw a video of the wild horse nylon bushing that replaces the outer bearing. Has anyone field tested that or should I just go with standard replacement bearings?

(('93-'97 Isuzu Rodeo's had Dana 44's and came with thick cut 4.11's from the factory. Pull the gears and install on your carrier.))
Should be plenty of those around. That sounds like a great option since I don't do alot of 4 wheeling anyway.

Thanks guys!

 

[turbotim2]

'93-'97 Isuzu Rodeo's had Dana 44's and came with thick cut 4.11's from the factory.

That is what I did, got the gears for $40 from someone on here. They worked out great. I did get a new master install kit from JBG with new bearings, shims, ring gear bolts, etc. and was worth the money. You'll need to replace the pinion bearings anyway and have to remove the carrier bearings to shim correctly too.

 

[Bartonatl]

@turbotim2: And all that (except the gears) came in the master install kit? pinion bearing and carrier bearing? Are the spindle bearings in that kit too?

 

[Nightstick]

@turbotim2: And all that (except the gears) came in the master install kit? pinion bearing and carrier bearing? Are the spindle bearings in that kit too?

No spindle bearings included in the diff rebuild kit. Just all the stuff for the innards of the diff. Might as well replace the ball joints while you're at it as well.

 

[turbotim2]

No spindle bearings included in the diff rebuild kit. Just all the stuff for the innards of the diff. Might as well replace the ball joints while you're at it as well.

What he said! ;D

 

[Bartonatl]

Got it!! 10-4 on the ball joints. I appreciate your reponses.

 

[Nightstick]

BTW, ya know you're gonna need setup bearings to rebuild the D44 right?

 

[Bartonatl]

Set-up bearings......yea I kind of remember reading that in an old thread and the response was " where do I get set-up bearings"?. So I'm guessing I need to get an extra set of new ones???

 

[turbotim2]

I think JBG and others sell a set up bearing to do this. I didn't use them but others do.

Here:

http://broncograveyard.com/bronco/i-29631-dana-44-set-up-carrier-bearings.html

 

[Apogee]

Complete Off Road has the D44 setup bearings for $69 here. I believe they're Yukon part #YT SB-D44, so any Yukon distributor should be able to get them, although COR seems to be pretty competitive on prices most of the time.

 

[Bartonatl]

Great. I'll add that to my "to get" list.

 

[Bronchole]

Hmmm, I usually just make my setup bearings from the old bearings. I chuck them up in a vise and attack the ID with a grinding stone. I was amazed at how fast the grinding stone worked. So fast that I got to make another set because I got a little bit happy on the first set