I have a 90 chevy 1/2 ton, and want to do a straight axle conversion. i want to use a dana 44 maby, and need someone to do the work for me. i would do it myself but dont have a lot of experience in this area. money is somewhat of an option. can anyone help me out?

I have a shop in sac and am getting ready to straight axle my tahoe. What 44 front? ford or chevy? I could give you a hand if needed. And do you realize how much it cost for a straight axle conv.?

only about 2,700-3,500 for everything not THAT bad.

-Thomas

The cost is dictated by how strong you build it, how many new parts you use and how much of of it all you can actually build(be it milling steering arms, gearing diff's, building hangars...).

$2,700-$3,500 is kind of a low number to swap in quality parts for a SFA on a fullsize, kind of sounds like YJ axles swapped under a Blazer or something:flipoff2:

ORU brackets -$750
Springs--------$500
shocks--------$200
steering-------$750
Axle-----------$600 if you're lucky for a D44
gears--f+r-----$300
elcheapolockers$750 for 2
Tires----------$800
__________________________
total----------$4650

And thats with no beer or labor or consumables.

ORU will quote you $7000 if they do it. Thats assuming you already have new brakes and hubs too.

Ok if u pay 4700 for a SAS dana 44 with no tires/rims, you better be gettin a lifetime warrenty to!!
I did it the long way, chevy dana 44 208 t-case made everything myself and sold my old IFS lift and im only at spending 550, The junkyard is my friend!! Get a reverse drive axle and stick with your stock t-case, get 70-85 chevy 1/2 ton rear springs, front rear sping hangers gonna need two sets or three sets if u wanna do a rear shackel reversal to match your front lift. For steering your gonna need a flattop knuckle and pony up the dough for a high steer, or make your own drag link, it was pretty easy... And then your done....

There is a guy in another forum who just finished his and he had a lot of money into it, however, he bought new wheels, tires, rear axle, drive lines and a D60. Anyway, he went all out with his and I think his total build tally was right around 5k.

Your looking at 3500.00 in parts from ORU Not including Hydraulic ram assist, + Dana 44-60 + rear springs, shocks, brake lines and drivelines. DOn't forget you need to change the rear end to match also. If you go 8 lug

Ok if u pay 4700 for a SAS dana 44 with no tires/rims, you better be gettin a lifetime warrenty to!!
I did it the long way, chevy dana 44 208 t-case made everything myself and sold my old IFS lift and im only at spending 550, The junkyard is my friend!! Get a reverse drive axle and stick with your stock t-case, get 70-85 chevy 1/2 ton rear springs, front rear sping hangers gonna need two sets or three sets if u wanna do a rear shackel reversal to match your front lift. For steering your gonna need a flattop knuckle and pony up the dough for a high steer, or make your own drag link, it was pretty easy... And then your done....

And that just reinforces the idea that it depends on how many new parts you use, how strong you built it and how much of it you do on your own.

$4650 for a HP d-drop axle, tires, lockers front and rear, new gears, premade brackets, bolt up steering, shocks, springs is about right for new parts.

If you play your cards rights, you can do a SAS for pretty cheap, AND still have good parts into and be 100% safe. A D44 will hold up with 36 and under tires, or with modest wheeling. Inexpensive and ORU don't belong in the same sentence. Not saying they suck or anything, be to me, just too expensive for what they have. Get a Ford HP44 out of a 3/4 ton, or a regualar cab 1/2, both have leaf springs instead of coils. Using a Ford axle will allow to keep your t-case, and the speedo will work. Like silversas13 said, get the front hangers for the rear springs to use for the rear hangers for the front springs. I think those hangers there are the hardest part about the whole swap. The front is easy, use a 2x3" tube, weld two tabs on either side for the spring mounts. Should be able to find a 73-87 GM in a yard that has a lift on it, get the front springs, or get the rear springs. Use a GM 3-piece tierod, shorten it for a draglink. PartsMike has crossover arms for a 44 for around $100 IIRC, and sells flattop knuckles too. If you buy everything from ORU you will spend over $10k in parts, probly double for labor. IF the search comes up, search for SAS, that are a shitload of posts on this subject, and will find all the info you need. Got any questions, this is the place to ask. Good luck, and post some pics.

Well since this is already going.Can someone post a complete list of what is needed. I see a need for: Front axle,springs,brackets,steering correction,brake lines and new driveshaft. I plan on keeping mine as low as possible 4"-6" so I can continue to tow my rig with it. I also don't plan to pay anything for the D60 :cool2: . I may build my own brackets if I can get some ideas.Since mine is an 01' HD there's not as many people who have cut them up.

Like BGGRN said its all in the application and wat new parts u need.
Since u got the F. Dana 60 your gonna need:
F/R gears
New hubs/bearings
driveline
rear front73-87 spring brackets 2 sets
for a small lift id use just normal front springs
brake lines, calipers, rotors/pads
build front crossmember if needed
flattop knuckles sent my passenger off to get surfaced and threaded for 60 on ebay.
get chevy tie rod for drag link shorten and retap it, or i used a 67 landcruiser tie rod for my draglink and worked perfect.
And a bunch of labor, and about two weekends to do this..
And im doin my build on another forum and got some pics of the brackets i built will post tomorrow...

Here's my list
Front ford dana44 high pinion from 3/4ton $100.00 junk yard
Warn standard hubs $60.00
ORU straight axle conv. $813.00 shiped
SKY Manufacturing crossover $375
Superlift 8" sping's from 73-87 chevy $121.00 each (4wheel parts)
Cut and turned front 16 degree's $250
U-bolt's & spring plate's $50.00 Local spring shop
Chevy knuckle's and outer's $75.00 junk yard
Braided steel brake lines $100.00 4wheel parts
4.56's front and rear apx $350.00
Used 38's and 15x14 wheels $500.00
Front driveshaft extended $100.00 got lucky no cv needed
There are many misc things such as brake's & ball joint's you may also need to replace.
THIS IS JUST FOR THE FRONT! The only thing that really set me back was ORU conv, but you could make your own.

That's not too bad.I already have lots of spring hangers and new wheels. It looks like I'll need springs,brake lines,crossover,driveshaft,u-bolts,ect. Shouldn't cost me too much if the 73-87 shngers will work on my D-Max.

what will be involved if i want to flip a chevy 60 over, i called randy's ring and pinion and they said it can't be done but i've seen people do it. would it be easier to throw a right output transfer case in, what would be involved, do they make a adapter or what??

It would be easier to just swap to a 89-91 K5 NP241 p-drop, depending on your fab skills it might not be cheaper though.

Here's my list
Front ford dana44 high pinion from 3/4ton $100.00 junk yard
Warn standard hubs $60.00
ORU straight axle conv. $813.00 shiped
SKY Manufacturing crossover $375
Superlift 8" sping's from 73-87 chevy $121.00 each (4wheel parts)
Cut and turned front 16 degree's $250
U-bolt's & spring plate's $50.00 Local spring shop
Chevy knuckle's and outer's $75.00 junk yard
Braided steel brake lines $100.00 4wheel parts
4.56's front and rear apx $350.00
Used 38's and 15x14 wheels $500.00
Front driveshaft extended $100.00 got lucky no cv needed
There are many misc things such as brake's & ball joint's you may also need to replace.
THIS IS JUST FOR THE FRONT! The only thing that really set me back was ORU conv, but you could make your own.

Shocks gonna cost you too.

what will be involved if i want to flip a chevy 60 over, i called randy's ring and pinion and they said it can't be done but i've seen people do it. would it be easier to throw a right output transfer case in, what would be involved, do they make a adapter or what??

Cut out the tubes and swap sides. Then if all is done correct you can have the correct caster and camber and also re-use the shafts. That's what I did, but alot of people will tell you to use a jig for re-welding it. I didn't, but I got a total of $500 in my fully fuctioning junkyard beast.

Id do that swap your tubes on your axle, use a p-drop t-case 241 or i used a 208 lower drop angle which is always better, make sure u get the right spline for the 208 they make two a 27 or 32 700ra use 27 and t400 use 32.

Since we're on the price topic
ORU kit $750 +shipping, can't remember how much
Springs $40-junkyard
Dana 60 $+/- $2000, completely rebuilt
Crossover arm $200 ORU, much cheaper places out there
Draglink/tierod $100 Got everything out of a j/y, shortened a 3 pc tierod
Shocks $85 Some brand from Autozone, measured length, looked for the closest, mounts are quite the same, but it works who cares
Stainless brakes lines/fittings $80 local speed shop
Driveshafts $100 +/- Most I got for free, but did get new joints
Tires/rims $600

I know I'm forgetting stuff, but I just woke up and only had a 1/2 cup of coffee so far, and can't remember all the stuff I did. By far the most expensive will be the kit, or the axle, depending on what you want to use, and your location. The HP I got for my 97 (if I ever do the swap) I got the whole truck for $100. Some of the parts you can get used, like my front springs. I needed something other than the stupid 12" Supercraps, and found a 4" set in a yard. Truck has about a 7" lift, so it sits about right, for now. Lifting the rear is easy, either homemade shackle flip, or if you want to buy a kit it's only $175 or something. Now alot of stuff on this is used, at the time I couldn't afford to buy new. For the tierod/draglinks, I think I found 3 new ends, and bought one. So it's not like they are used wore out peices. I have a friend that owns a j/y, so that's where I get alot of free stuff. At another yard, I get deals cause I go there alot. Also have alot of connections.

Don't think SAS works in the search but..........

American did a huge compilation thread of Straight Axle stuff
called 88-98 SAS a long time ago. Luckily I have a brain that retains that shit. SO a simple search for threads started in Chevy by American and viola!!!

Here is it. Tons of good stuff.

http://www.pirate4x4.com/forum/showthread.php?t=252455


Just to add some laughs to the thread, there is a shop here in Houston called Cutten Customs. The seem to mainly do lifts.
I had a chance to stop in there a while back, since I was up on there side of town. I have a HP60, I have tires and wheels. I can go buy the ORU kit if I wanted. You know how much these guys qouted if I brought them the ORU kit, and my axle and what not? 10K!!!!! I rarely laugh in peoples faces, but it was totally involuntary.
If you don't have the fab skills or the time the ORU kit is reasonable from what I've been told. Since its all a bolt in affair with their kit, you should be able to strip down your IFS on a Saturday morning, and by Sunday night have it off the jackstands and driveable. Maybe not fully functional, but back on the road.

look man i took a o1 chevy silverado put a dana 44 in the front on 12" coil overs ft & bk, metal, parts, and welding supplies cost me less than 6,000$ which all the work was done myself and believe me it was definatly the way to go!

There is a guy in another forum who just finished his and he had a lot of money into it, however, he bought new wheels, tires, rear axle, drive lines and a D60. Anyway, he went all out with his and I think his total build tally was right around 5k.

if your taking about brian on 4wp, he had 17K in his i remember him saying.