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:
Solid axle conversion - This is generally a huge and/or
an expensive undertaking. It is also generally the strongest and
heaviest option.
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.
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.
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:
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.
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.
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.
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
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
(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
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
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
Diagram # |
Description |
Interchange |
Dana / Spicer part number |
Dana’s Description |
3 |
Front pinion oil slinger |
CDF |
34643 |
SLINGER - PINION BEARING INNER |
4 |
Front pinion bearing and race |
CDF |
70604X |
INNER PINION BEARING KIT |
5 |
Pinion shims |
CDF |
706359X |
KIT - PINION BRG ADJ SHIM |
6 |
|
D |
708020 |
KIT - DIFF & PINION ADJ SHIM |
CF |
706375X |
|||
|
|
CF |
30982 |
BAFFLE – PINION BEARING |
7 |
Rear pinion bearing and race |
CDF |
706045x |
OUTER PINION BEARING KIT |
8 |
Pinion thrust washer |
CDF |
42737 |
THRUSTWASHER - BEARING |
9 |
Pinion seal |
CD |
42449 |
SEAL - PINION |
10 |
Pinion Yoke slinger |
CD |
34592 |
SLINGER - END YOKE |
12 |
Pinion nut washer |
CDF |
30275 |
WASHER - PINION NUT |
13 |
Pinion nut |
CDF |
30271 |
NUT - PINION |
17 |
Diff cover bolt |
CDF |
34822 |
BOLT - CARRIER COVER (QTY 10 |
18 |
Diff cover gasket |
CD |
34687 |
GASKET - CARRIER COVER |
20 |
Diff main bearing cap bolt |
CDF |
48632-1 |
BOLT - DIFFERENTIAL BEARING CA |
21 |
Carrier bearings |
CDF |
706047X |
DIFFERENTIAL BEARING KIT |
22 |
Carrier shims |
D |
708012 |
KIT - DIFF BRG ADJ SHIM (INC 1 |
CF |
706378X |
|||
24 |
Ring gear bolt |
CD |
30266 |
BOLT - DRIVE GEAR (QTY 12) |
26 |
Spider gear |
CDF |
34367 |
PINION |
27 |
Side gear thrust washer |
CDF |
34729 |
THRUST WASHER |
28 |
Spider gear thrust washer |
CDF |
34730 |
THRUST WASHER |
29 |
Roll pin – cross pin |
CDF |
44810 |
LOCK - DIFFERENTIAL SHAFT |
30 |
Carrier Cross pin |
CDF |
30263 |
DIFF SHAFT |
31 |
Inner axle seal |
CD |
36487 |
SEAL & GUIDE TUBE |
|
King pin rebuild kit |
CD |
706395X |
KIT - KING PIN PARTS |
32 |
Upper kingpin seal |
CD |
620058 |
SEAL - KING PIN - UPPER |
33 |
Lower kingpin seal |
CDF |
37305 |
RETAINER - GREASE |
34 |
Lower kingpin bearing oil seal |
CDF |
41777 |
SEAL - OIL |
35 |
Lower kingpin bearing and race |
CDF |
706150X |
KIT - BEARING - KING PIN - L |
41 |
Upper kingpin cap bolt |
CDF |
30875 |
NUT - HEX TAPERED |
44 |
Upper kingpin cap gasket |
CDF |
37307 |
GASKET - KING PIN CAP |
44 |
Upper kingpin cap |
CDF |
620132 |
CAP - KING PIN - UPPER (RH ONL |
45 |
Kingpin spring |
CDF |
37300 |
SPRING - PRESSURE |
46 |
Kingpin spring retainer |
CDF |
620180 |
GEAR |
47 |
Upper kingpin bushing |
CDF |
41886 |
BUSHING - KING PIN |
48 |
Kingpin |
CDF |
37302 |
PIN - KING |
Spindle stud |
CD |
37879 |
BOLT - HEX |
|
50 |
Lower kingpin cap |
CDF |
37299 |
CAP - KING PIN BEARING LOWER |
51 |
Lower kingpin cap lockwasher |
CDF |
500357-13 |
LOCKWASHER (KING PIN CAP - LOW) |
52 |
Lower kingpin cap bolt |
CDF |
500412-13 |
BOLT - HEX (KING PIN CAP - LOW |
53 |
Stub shaft slinger |
CD |
37308 |
SLINGER |
54 |
Spindle bearing and seal kit |
CD |
700014 |
KIT - SPINDLE |
56 |
Inner spindle seal |
CD |
620062 |
SEAL - NEEDLE BEARING |
56 |
Spindle thrust washer / spacer |
CD |
37312 |
SPACER - WHEEL BEARING SPINDLE |
57 |
Outer spindle seal |
CD |
37311 |
SEAL - OIL |
58 |
Spindle bearing |
CDF |
620063 |
NEEDLE BEARING - SPINDLE |
59 |
Spindle nut |
CD |
36880 |
NUT - BRAKE MOUNTING |
60 |
Hub seal (inner wheel bearing seal) |
CD |
48816 |
SEAL - GREASE |
62 |
Inner wheel bearing and race |
CDF |
706411X |
INNER WHEEL BEARING |
63 |
Outer wheel bearing and race |
CDF |
706074X |
INNER WHEEL BEARING KIT |
68-72 |
30 spline drive flange kit |
CF |
707083X |
KIT – DIFF PLATE AND DISC (T/L) |
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
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)
6-11. Steering Knuckle And Arm Maintenance (All Except M1009) (Con’t)
6-11. Steering Knuckle And Arm Maintenance (All Except M1009) (Con’t)
(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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