For those of you that tell me to search, get over it. I already did, and the answer was not there.

I have a 1991 F250 Diesel. I want to do a SAS on it because the front TTB is crap. I can't afford the D60 for the front end, and want to do the D44 for it. What is involved in doing this swap? Is this a basic weekend job? What axle do I need for this? How about steering?

From my understanding is, the older D44's have a narrower spring width, which means I would have to reweld the spring perches further out so that I can use it. I would have to cut off all the old TTB hangers off the frame, and use the stock steeriong from the axle donor. I can build a new panhard, no problem. Am I just about right?

Thanks
Dima

the ttb hangers shouldn't be in your way but wouldn't be bad to get rid of them but yes you have covered the bases fairly well, honestly unless you are finding a 44 for next to free then save your $$ for a little while and find a 60 later to save you from doing 2 axle swaps and the time & $$ involved in doing it twice.

I am not wheeling this thing. It is only a daily driver and tow rig. How much strain will I put on my front end from driving it every day. This will NEVER see off road duties.

Dima

Seems the answer is here

http://www.pirate4x4.com/forum/showthread.php?t=145141

but I wont' tell you to search

for steering you can just use '86-97 F350 stuff, that will work the best due to differences in steering box placement pre and post '79

EDIT: I guess I'll add I just moved spring perches out to the later, wider 36" spacing on a '78 D44HD (leaf sprung). The passenger side one you just cut and relocate. The driver's side, I just put a new, narrower perch right next to the one cast into the pumpkin. In fact, I just welded this new perch on three sides 'cause I didn't feel like dealing w/welding cast w/MIG, and I think the three sides is perfectly sufficient. The driver's side leaf rests about 2/3 on the new perch and 1/3 on the old cast-in perch. A tiny bit of grinding was necessary to get the u-bolt to run up, rather than down as it does in stock form. Spring plates were custom.

So in reality, I can do this in a weekend at my house right? I have access to a plasma cutter to cut off all the old crap.

Thanks
Dima

yes it is a weekend job and for a tow rig a d44 will be plenty

so you want to downgrade the bearing size and weight carrying capacity of your tow rig??

Explain how the front end will make my load carrying capacity less? As far as I am concerned, I still have the sterling rear, and that is where all the weight will be.

Dima

If you do come across a leaf sprung 44, I'd appreciate this: what exactly do you come up with center to center on holes for the leaf pins stock? Second, do you measure the same distance on each side from the center hole to the inner knuckles (or location of your choosing?), ie are the spring perches such that the axle would be perfectly centered under the truck stock?

I know what the specs say, I just have some suspicions, but by the time I discovered I wanted to measure stock, I had already cut the passenger spring perch off.

Also, while you're doing your SAS you might consider a shackle reversal, you'll gain a better ride and be able to ditch the track bar. Or keep the shackles up front but ditch the a-frame shackles, which should also allow you to get rid of the track bar

under "shackle kits"
http://www.offroadunlimited.com/new/parts/parts_inside_index.html

This is an F250, no track bar needed. I am considering doing the Reverse Shackle setup. Iw ill get you all the info you want.

Dima

You'll need a track bar if you keep the stock shackles on your F250; those things are the opposite of STABLE

So what do I do if I don't want to do a reverse shackle? Do I just beef up those shackles?

Thanks
dIma

So what do I do if I don't want to do a reverse shackle? Do I just beef up those shackles?

IMO you'd want to go to an H style shackle. I just don't see how the stockers are gonna locate the axle laterally

somewhat poor shot of the stock front-mounted shackle:
http://www.superford.org/getfile.php?id=89870&toggle=fullsize&f=SwampDonkey 006.jpg

Explain how the front end will make my load carrying capacity less? As far as I am concerned, I still have the sterling rear, and that is where all the weight will be.

Dima

There is a reason why diesels and high gvw F-250's use a 50 up front, and not a 44.. Unless yours is one of those ultra rare diesels with a 44 under it..