Narrowing a Dana 44 - Pirate4x4.Com : 4x4 and Off-Road Forum

waverous · 07-20-2003, 09:14 PM

I want to investigate just how difficult it would be to narrowing it for my 73 Bronco. I have a HP Dana 44 with cast perches from a 78 Bronco just lying around so I was thinking give it a shot. Anyone have a good write up on the process?

Rogue Bronco · 07-20-2003, 11:34 PM

Dont waste time with the '78-'79 F-150/Bronco housing. It can be done, but an older F-150 housing would be the way to go.
'Mr.N' is a D44 junky, hes got a site with all kinds-o-info on the varying D44 housings & junk.
The '78-'79 housings are 1/4" wall between the pumpkin and the cast section, then 1/2" wall from cast section to knuckle, how retarded is that?!?!
If it wasn't so late here I'ld post his link, but I'm tired so yur on your own

try searching his name, or D44 (Im sure it'll pop up)

alx · 07-21-2003, 04:01 PM

heres some pics of how i narrowed mine takes about 2-4 hours
lots of grinding and a BFH will do it

narrowed D44 with cast wedges

hurry the web site is goin off line , cost to much to keep it

Mr.N · 07-21-2003, 05:44 PM

Alx has a some nice pics showing the how to shorten a 78-79. Just remember should need to line up the other end of those arms, which might lead to custom axle shafts.

broncobsession · 07-21-2003, 07:18 PM

Quote:

Originally posted by alx
heres some pics of how i narrowed mine takes about 2-4 hours
lots of grinding and a BFH will do it

narrowed D44 with cast wedges

hurry the web site is goin off line , cost to much to keep it

Never got around to that write-up, eh? I am also planning on stuffing one under my EB and had similar Q's as waverous. After grinding down, just whack it with a BFH and the cast part comes off? What did you use to cut the tube itself for the narrowing? I was just planning on sending the p-side inner shaft to Moser for cut and re-spline to the new length. The driver's side is ok as is, right? TIA

alx · 07-21-2003, 07:40 PM

i just ground on the weld there untill you can see a hair line crack and then wacked the wedge off witha 10lb wood spliter

put my chop saw up there stuck the housing in it and cut it off

its not a super tight press fit but it does require a little help putting the end back on .

be sure you sricbe a line down the center of the tube so you can line it back up after you put it back on ,then put a solid rod in the ujoint holes and check the camber ( cheap magnetic angle finder)make the cut side match the other or check it before you cut it and make it the same .

never really had time to write it up , to lazy i guess

save the pics the site is goin off line ,but ill have a new one in oct.
when i finish up a few things and can spare the change for it

u2slow · 07-21-2003, 08:44 PM

Quote:

Originally posted by alx
put my chop saw up there stuck the housing in it and cut it off

You stole my secret!

07-20-2003, 09:14 PM	#1 (permalink)
waverous Registered User Join Date: Nov 2002 Member # 14972 Location: Aurora CO Posts: 5	Narrowing a Dana 44 I want to investigate just how difficult it would be to narrowing it for my 73 Bronco. I have a HP Dana 44 with cast perches from a 78 Bronco just lying around so I was thinking give it a shot. Anyone have a good write up on the process? __________________ "Do not go where the path may lead, go instead where there is no path and leave a trail." Ralph Waldo Emerson (1803-1882)

07-20-2003, 11:34 PM	#2 (permalink)
Rogue Bronco Registered User Join Date: Mar 2002 Member # 10622 Location: Vancouver Posts: 400	Dont waste time with the '78-'79 F-150/Bronco housing. It can be done, but an older F-150 housing would be the way to go. 'Mr.N' is a D44 junky, hes got a site with all kinds-o-info on the varying D44 housings & junk. The '78-'79 housings are 1/4" wall between the pumpkin and the cast section, then 1/2" wall from cast section to knuckle, how retarded is that?!?! If it wasn't so late here I'ld post his link, but I'm tired so yur on your own try searching his name, or D44 (Im sure it'll pop up) __________________ '85 Bronco III

07-21-2003, 04:01 PM	#3 (permalink)
alx Registered User Join Date: Dec 2000 Member # 2414 Location: sheboygan ,wi. Posts: 661	heres some pics of how i narrowed mine takes about 2-4 hours lots of grinding and a BFH will do it narrowed D44 with cast wedges hurry the web site is goin off line , cost to much to keep it __________________ is there any way for me to just stay in hell ? that way when things get good i wont have to fall so far when the shit hits the fan again.

07-21-2003, 05:44 PM	#4 (permalink)
Mr.N Registered User Join Date: Sep 2000 Member # 1635 Location: Minne-so-cold Posts: 3,961	Alx has a some nice pics showing the how to shorten a 78-79. Just remember should need to line up the other end of those arms, which might lead to custom axle shafts. __________________ Proud Catholic \| My Dana Articles and Info -> http://77cj.littlekeylime.com/web_rs44.html

07-21-2003, 07:40 PM	#6 (permalink)
alx Registered User Join Date: Dec 2000 Member # 2414 Location: sheboygan ,wi. Posts: 661	i just ground on the weld there untill you can see a hair line crack and then wacked the wedge off witha 10lb wood spliter put my chop saw up there stuck the housing in it and cut it off its not a super tight press fit but it does require a little help putting the end back on . be sure you sricbe a line down the center of the tube so you can line it back up after you put it back on ,then put a solid rod in the ujoint holes and check the camber ( cheap magnetic angle finder)make the cut side match the other or check it before you cut it and make it the same . never really had time to write it up , to lazy i guess save the pics the site is goin off line ,but ill have a new one in oct. when i finish up a few things and can spare the change for it __________________ is there any way for me to just stay in hell ? that way when things get good i wont have to fall so far when the shit hits the fan again.

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