Ford Bronco Solid Axle Page

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Ford Bronco Solid Axle Page

Axles

5 Lug to 8 Lug 44 TTB Conversion

There are a number of ways to convert your front end to an 8 lug pattern:

1. Solid axle conversion - This is generally a huge and/or an expensive undertaking.  It is also generally the strongest and heaviest option.
    

2. Conversion to a Dana 44 HD or Dana 50 TTB setup form a F-250.  This requires conversion to leaf springs or creativity and customization to allow for radius arms and coils.  This can be expensive and requires sometimes difficult to locate parts depending on where you live in the world.  And for the cost and effort you basically just get 3 more lugs on each side.
    

3. Some have considered a custom wheel adapter from 5 to 8 lugs.  I made an attempt and designing one a long ways back before my solid axle conversion and gave up.  It just didn't seem safe.  I contacted the big wheel adapter fabricator of the day and they said it was impossible.  That said, it can and has been done.  You simply make 2 adapters.  One that fits the hub pattern and anther that fits your wheel pattern.  You then map out holes between these two different lug patterns that will allow for mounting these two different adapters together.  For a 5 to 8 lug pattern, your adapter to adapter holes will not be evenly spaced, unless you make a very wide adapter.
   
   A 5 x 139.7 (5.5") 1/2-RH to 8 lug 6.50" X 2.00" Wheel Adapter looks something like:
   
   
   This can save a bundle of money and headache, but still doesn't look right for heavy abuse applications.  Having one of these may also allow you to run different lug pattern wheels front and rear, yet still only need to carry a single wheel.
    

4. You can take a 3/4 Dana 44 spindle, hubs and brakes and mount it on your 44 steering arm after you remove your caliper wings.  This would be the best compromise allowing for a stock strength setup with minimal effort not requiring any special or custom parts and without adding a ton of weight to your front end. 
   
   First off, an F-250 has a different sized steering arm than used on a 1/2 Ford.  Making a Ford 3/4 steering arm work, you would have to get creative on the steering arm with a welder - a place most would not want to mess with.  To make this conversion work, you will need to find a straight axle 3/4 ton Chevy 4x4 donor axle/truck (NOT a late 1980's with the IFS).  You will need to make sure that the donor axle you use has the caliper bracket in front of the spindle and not inbetween the spindle and knuckle.  Once you have your parts, strip your Ford steering arm of everything, including the spindle studs.  Cut the break caliper brackets off.  Now install everything from the spindle studs out with your Chevy parts.  8lugswap
   
   Wish I knew this trick back in the day.

8 to 5 lug Conversions

Every once in a while, someone wants to fit 5 lug wheels on an 8 lug axle.  There are a number of ways to do this:

1. Generally the most economical way to deal with this is to go purchase a pair of 8 lug wheels.  These should fit without issue and you can get just about anything in 8 lug now a days, to include 15 inch wheels with beadlocks.
    

2. There are adapters that allow you to go from 8 to 5 lugs.  These are actually two adapters in one.  One mounts to the 8 lug hub and the other mounts to the wheel.  Offset holes are configured to allow the adapters to mount together.
    

3. Hubs can be modified to allow for different bolt patterns.  You may need to fill in a hole or two as the bolt patterns will overlap at least at one point.
   
   
    

4. Depending on what axle you have, you may be able to use 1/2 ton hubs that may fit perfectly and allow you to mount unmodified wheels
    

5. Most axles, front or rear, can be outfitted with custom hubs that can have just about any bolt configuration.
   
   
   
   pirate4x4 322657
    

It is important to note that if you change your bolt pattern, your wheel may still not fit over the center hub and require that you enlarge their center hole if you plan to run them.  This can be done on a lathe or with a hand grinder with mixed results. 

Dana 60 Axle Stuff

CTM Racing Products, Inc.
32991 Calle Aviador #E
San Juan Capistrano, CA 92675
Phone:. 949-487-0770
Fax: 949-487-0772
info@ctmracing.com
ctmracing.com

Be aware that these u-joints are designed to use "full-circle" snap rings and so will require a little machining of the ears of the yokes of stock shafts to allow the snap-rings to fit, or the use of custom D60 front shafts designed for full circle snap rings.
These u-joints are also much stronger than stock Spicer shaft yokes and are rebuildable.

Superior Axle and Gear
1477 Davril Circle
Corona, CA 92880
Phone (888) 522-2953
Fax (888) 747-2953
superioraxle.com
ron@superioraxle.com

Dana 60 Big 35 Spline Inner and Stub Axle upgrade

4wdfactory.com

(512) 759-6267

off-road.com/chevy/tech/dana35spline

2 Standard Spicer D60 Ujoints: Part # 5-332X
1 Spicer 35 spline inner shaft (short side): Part # 660182-5
1 Spicer 35 spline inner shaft (long side): Part # 660182-6
2 Spicer 35 spline outer stub shafts: 382871
1 set of Warn hubs: Part # 38786 (pair of hubs)

sales@4wdfactory.com
pirate4x4 PR-35Spline review

broncograveyard yukon_chrome-moly_dana_60_outer_axle__35_spline

coloradok5 35splineupgrade

14 Bolt 1410 Yoke and U-bolt Kit from High Angle Driveline
highangledriveline 1350 larger end yokes 14 bolt full float Gm 1410 series u bolt style 89.00 28 degree's max #14b1410

pirate4x4 PR-1410_Yoke

Dynatrac

Sunray Engineering

Sunray Engineering 1550

Sunray Engineering sun 60

King Pin rebuild kits

drivetraindirect.com  - Spicer and bottom kingpins

partsmikeparts 60Front - bottom kingpins

offroaddesign kingpinspring-bushing.htm

offroaddesign Dana60frontaxleparts.htm

broncograveyard d60_king_pin_kit

Rumor has it that you can preload your bushing by adding as much as 1/8".  More may cause coil bind which is very hard on parts. An additional spring cup on the top of the spring adds about .060".

Front Dana 60 Axle Tech   pirate4x4.com Dana 60 info

Dana 60 top Kingpin Removal

To remove the top kingpin use a 7/8" hex rod bent into a giant Allen key, or

cut down a chisel with a 7/8" hex backing, drop it in the kingpin so that enough is exposed for a heavy duty socket - and use a 3/4" drive socket on a t-bar with a cheater bar

Thing that don't work:

Several 7/8" nuts welded to a grade 8 bolt welded to a long bar - bolt and welds shear

Long chrome plated 7/8" (outer) lug nuts - outer corners get rounded off

1/2 drive ratchet, cheater bar and lug nut - 1/2 ratchet breaks

7/8" wrench, cheater bar and lug nut - wrench bends and/or rounds lug nut

Dana 60 Axle Shaft Outer Seal

Keeps dirt out of axle tubes on a Chevy Dana 60

Go to NAPA and ask for a Victor 47163 or a Napa part number NOS14887 (Differential Seal - Rear Axle)

More Dana 60 Axle Stuff

Bearing Locknut Socket Gm 3/4-1ton Truck Ford F-Series

Applications:
19851/2-1995 Ford F-series H.D. 3/4 and 1 ton Dana 50 IFS or Dana 60 front axle
1985-1995 Ford F-series 1/2 ton truck and full size Bronco with Dana 28 front axle
1982-1990 GM H.D. 3/4 and 1 ton trucks
Manufacturer: OTC DIVISION OF SPX CORP

???Dana 60 Front Spindle Nut Socket Napa #775-9025 (I don't know if this is 4 or 6 prong)
GM D60 spring plates Part numbers 370055 and 370056

Axle tube diameter. 3.125", wall thickness 0.5"

Pep Boys Motormite U-bolt part # 35661 - measures 5/8" x 8 1/4" x 3 1/8" fit perfectly a leaf spring pack that measures 2 1/2" and there is another 1/2" left on the bolts.

from pirate4x4 60_front

dana.com X510-8.PDF

CUCV Axle Stuff

Need parts - ask for parts for a 1985 (84-86) 1 ton Chevy

All GM / Chevy versions were passenger side differential, regular rotation (low pinion) gears, disc brakes, 35 spline inners, 30 spline outers, internal style hubs, and kingpin knuckles.

1977-87 K30 1 ton 4wd

1984-88 CUCV

1988-91.5 V30

Trucks, 1.25 Ton - Alternate Site
Army 1.25 Ton maintenance & operating manuals.

TM 9-2320-289-20

• 8-3. Front Locking Hub Replacement

• 8-4. Rotor And Wheel Bearings Maintenance.

• 8-4. Rotor And Wheel Bearings Maintenance (Con’t)

• 8-4B. Cleaning And Inspection

• 8-4C. Installation

• 8-4 Follow-On Tasks

• 8-5. Drum, Hub, And Wheel Bearings Maintenance

• 8-5B. Cleaning And Inspection

• 8-5C. Installation

• 8-5 Follow-On Tasks

• 8-6. Front Wheel Toe Alignment

TM-9-2320-289-34

• 6-11. Steering Knuckle And Arm Maintenance (All Except M1009)

• 6-11. Steering Knuckle And Arm Maintenance (All Except M1009) (Con’t)

• 6-11. Steering Knuckle And Arm Maintenance (All Except M1009) (Con’t)

• B. Assembly

• 6-11. Steering Knuckle And Arm Maintenance (All Except M1009) (Con’t)

• 6-11. Steering Knuckle And Arm Maintenance (All Except M1009) (Con’t)

• Follow-On Tasks

(1) M1008, Truck, Cargo, Tactical, 1¼ Ton, 4x4

(2) M1008A1 , Truck, Cargo, Tactical, 1¼ Ton, 4x4

(3) M1009, Truck, Utility, Tactical, ¾ Ton, 4x4

(4) M1010, Truck, Ambulance, Tactical, 1¼ Ton, 4x4

(5) M1028, Truck, Shelter Carrier, Tactical, 1¼ Ton, 4x4

(6) M1028A1, Truck, Shelter Carrier w/PTO, Tactical, 1¼ Ton, 4x4

(7) M1028A2, Truck, Shelter Carrier w/PTO, Tactical, 1¼ Ton, 4x4

(8) M1028A3, Truck, Sheller Carrier, Tactical, 1¼ Ton, 4x4

(9) M1031, Truck, Chassis, Tactical, 1¼ Ton, 4x4

Front Hubs

Position inner adjusting nut (5) with pin facing outward and tighten to 50 lb.-ft. (68 N•m) while turning rotor (9) to seat wheel bearing assemblies. Loosen inner adjusting nut and tighten to 50 Ib.-ft. (68 N•m). Back off inner adjusting nut far enough to install adjusting lock (6). Position adjusting lock with hole on inner adjusting nut pin. Install outer adjusting nut (5) and tighten to 160 Ib.-ft. (217 N•m).

Rear Hubs

Install adjusting nut (18). Tighten adjusting nut to 50 Ib.-ft. (68 N•m) while rotating hub (8) and drum (9) assembly to seat bearings (15 and 17). Loosen adjusting nut slightly to align for installation of key (7). Install key in adjusting nut, Install retainer (6) on spindle (11). Ensure that retainer is properly seated.

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