OK I've been sitting here researching for a few hours and I want to get out into the garage and work on my Dana 44. I've got it all figured out except which axle shaft length to cut my short side down to. I can either use a J10 shaft at ~16.75" (which is about 1.5" shorter) or a Dodge shaft at ~16.31" (about 2" shorter)

Here's my question, can I cut my housing down 1.75" and run either shaft? Will the extra or missing 1/4" hurt anything? I'm also hoping by being able to run either shaft I can find off the shelf alloys when the time comes. If it matters I'll be running a stock carrier welded up until I can afford a selectable locker. Thanks for any advice my brain hurts:confused:

Travis

Read some post on the Early Bronco guys swapping to a F150 shaft. The shaft is longer and many people have reported they have to trim it.

So I'd say not, don't do it. If your looking for a cheap solution run a 1980-1996 Ford F150 Dana 44 shaft. They seem to be giving them away around here. They are 15 23/32" long.

Thanks that's good info. The Warn chart says the F150 is 1/2" longer then the Bronc. I'm not happy with the way the caster is shaping up so I may just build the axle at 1 3/4" amd see what happens. Thanks for the info
Travis

Any other thoughts before I glue it together? What would I have more luck finding off the shelf alloys for; Dodge or J10?

Most D44 shafts have unused spline area, so you could prolly cut a shaft that was 1/4" too long and be OK

Yup just went out and did some measureing. My stock carrier has ~1/4" less spline then the shaft. Does anyone know if most selectable lockers are the same way?

the only way I see a problem is if the splines are not fully in the side gear or bottoms on the centerpin.
otherwise there is some fudge factor allowed