im getting close to starting my sas on my 2001 f150, my plan from the beginning was to use a d44 and run 38s. after thinking about it ive decided to use a d60 and run 40s. i need advise on what 60 to use as ill be hitting the graveyards this weekend. also do yall think it is worth it to spend the money on a 60 or just get a d44, i have the 9.75 rearend and think a 60 makes sense espicially if i run 40s. keep in mind this a DD and only sees mud on the weekends.

When doing your swap you need to sit down and think it through or you will run into lots of things that will make you wish you never started it. I did a sas on an 99. As far as rear end choice. It would be easiast to find a sterling 10.25 out of a F250 with a tone ring for your rear sensor. I'm not sure what other axles will work but I know it worked well in mine and I retained my speedometer and transmission shift points. Are you going to leaf spring it, 4 link, ect....I am anxious to hear how the 04' that BTF is building turned out with all the sensors the 04's have and how they got around them.

ill be using coil springs and custom leafs in the rear unless i win the lottery or some thing and can get coilovers:D . is it possible to do it without swapping the rear axle?

It sure is possible. One ton rear axles are easily obtainable for around $200. You are going to have to regear if you are planning to run 40's. If you are on a budget It might even be a good Idea to find a matching front and rear off a one ton truck with maybe factory 4.10 gears. Later you can upgrade to maybe some 5.13's with a locker.....The possiblities are endless

Isn't the 9.75 a metric bolt pattern? 5 x 135mm.

i have blown up my dana 44 under my bronco more than once with just
36's.
when i look back, i could have done a d60 leaf set up for no more than my coil with nice radius arm d44 cost me.

buy my f350 and be done with it...

http://www.pirate4x4.com/forum/showthread.php?t=470948

i could have done a d60 leaf set up for no more than my coil with nice radius arm d44 cost me.

I'm with broncogearhead.

Leaf-60 swap. Cheap n strong.

ideally the narrow perch width is best to get more flex and tire clearance in full turn....plus a kingpin is a big plus.

but sometimes you just gotta settle for what you get a deal on...i got a D50 front and 10.5" rear with discs for $800 with 1000 miles on em.werent nearly my ideal axle, but it works fine for me. You will want either a 10.25 or 10.5" rear....depending on what front you use(lug pattern). They both have a tone ring like your 9.75.

Id ditch the D44 idea, why do all this work to still have 1/2ton stuff.

I like leafs also, but either will work just fine with preparation....just find an axle and go from there.

As several people have stated above, try as hard as you can to skip the d44 idea. I went with a d44 front in my XJ, and I really regret it, seeing as starting with a d60 would have been a much smarter and stronger axle to begin with. Try finding some military surplus vehicles in your area, and see if you can find some big axles out of them. I'm not talking rock wells, but anything big enough to be considered an upgrade.

are you planning on wheeling it cuz if its gonna stay on the pavement and light wheeling just do a 44 and leave it open if you plan on actually wheeling it do a 60 for sure