Ford 44 research info

[JGVABronco78]

In the process of trying to look up alternate models to get a donor for a 76/77 HD stub, I found a lot of interesting similarities in Ford Dana 44 axle shafts. This is a compilation of axle numbers and dimensions for all open knuckled Ford Dana 44 axles from 73 to 79 except the 77 and prior Broncos which only differ from the 73 through 79 trucks in that the inner axle shafts are shorter. They use the exact same stub.
Note: each of these axle assemblies use a 1-1/4 dia. X 19 spline stub and a 1-5/16” x 30 spline inner axle shaft, and a 5-760X u-joint(formerly 5-297X).

Axle assy. #29508-1X and 2X: Found exclusively on 76/77 F-250's with full or part-time hubs according to XGI on Dana expert site.*
Stub: #37951; length 10.66”
1X, p-side #27905-35X; length 34.75(overall 45.41”)
2X, d-side #27905-31X; length 18.62(overall 29.64”)
* Anyone with a 76/77 full-time F-250 please chime in. I'd like to know if they have a normal full-time disc and cap or a bolted on external flange? If the later model wheel hubs will fit this spindle that would mean that the shorter later model stub could be used, and the donors for stubs would then be virtually limitless.

Axle assy. #660003-1,2,3,4: 1 and 2 are found in all 73 thru 78 F-100/150 regular cab, and 78 Bronco, 3 and 4 are found in 77/78 ½-ton SC, and all 77.5 thru 79 F-250.*
Stub: #620005; length 9.72
1, p-side ½ ton, 27905-3X, length 33.91(overall 43.62)
2, d-side ½ ton, 27905-4X, length 18.91(overall 28.62)
3, p-side 3/4 ton, 27905-35X, length 34.75(overall 44.47)
4, d-side 3/4 ton, 27905-31X, length 18.62(overall 28.34)
* Note: all axles use the same outer stub, the coil-spring and leaf-spring models differ by total length due to the slightly longer inner shafts. Also Bronco only uses this assembly number for the first half of 78 only, which there were other documented mid-year model changes such as headlight style. See next assembly. Also note the same inner shafts are used as 76/77.

Axle assy. #660124,1,2,3,4: same as above except stub p/n changed to 620200, found in 78.5/79 F-150, SC and Bronco. All dimensions identical to previously listed. I believe this is the cut-off point where they changed from Spicer hubs to Warn hubs, and that the snap ring groove may be slightly displaced. This would explain why some say 77 was the last year for Spicer, and others like myself say 78 was the last year, and why some models accept certain aftermarket hubs easier than others.

Axle assy. #660106,1,2,3,4: identical to prior two entries except again stub p/n has changed(#620160). Dana expert list this axle only for 79 F-150SC and 79 F-250, and identifies -1 and –2 which is an obvious misprint because the –3 and –4 are the assemblies used on the leaf-sprung. Out of 6 BOM’s for 150SC, only one used this assembly, and out of 12 BOM’s for F-250, only 2 used this assembly. The rest were 660124. My gut feeling on this was that the original intention was to keep the Spicer hubs all the way through the 79 MY for 250 and SC, but for whatever reason, at least one plant started using the Warn hubs and generated a new part number 660106. Since this is a much later catalog, 660106 was probably superceded by the 660124, which I believe is a later model series but largely identical. I'm still curious about the 106 though. My thought is that they were left in for the full-time flanges due to the spacer requiring a specific snap-ring location, but the 003 would have been much better suited for that, if my theory is correct, because the 106 would have had the groove moved for the Warn hubs. The only way this theory would hold up is if they modified the full-time spacer in 78.5 when they moved the groove, and even now neither of the 124 grooves will work, or its just an oversight or misprint. Time will tell I hope.

The hard data in this thread was all derived form the Dana catalogs provided on the Dana Expert site found at http://www2.dana.com/expertforms/depdf.aspx?prod=AXL

[JGVABronco78]

Summary from above info:

I realize this may seem like a lot of speculation, but the dimensions do not lie. They use the same dimension stub from 73 to 79 except 76/77 ¾ ton HD’s which we know are 1” longer due to external hubs, but which axles also use the same inner shafts as the later leaf-sprung axles. The only thing that changes is the part number for the stubs, which when verified, I believe will show something to do with the Warn versus Spicer hubs, most probably the snap ring. It could be as simple as the location between 003 and 124, and the thickness between 124 and 106, but that’s enough speculation until the measuring is done. Also I’d like to know if later model hubs fit on 76/77 spindles. The brake bracket is identical to the later model 44 AND the 60 bracket, except that the hole is smaller due to smaller spindle boss diameter. I’m eagerly awaiting the teardown of my 79 F-250 to check the spindle boss diameter of it, because I hear that the 44 and 60 brackets will interchange for 78/79. That tells me that the 77.5-79 D44 spindle must have a larger boss than the 76/77 in order to have the proper fit in the bracket. Also it has the Warn hubs, so I can compare it side by side with my 2 78 ½ ton stubs to see what generated the new part number.

Any one with proof positive facts to support or disprove any of the speculation, please feel free to join in. I will update as I get more teardowns complete, or if I find other supporting or conflicting data in print.

Edit: In my Ford specific Dana manual dated June 78, it only lists the 660106, so like the 760X joint, I'm going to have to believe that the 600124 assembly number superceded it, and the only reason the 600106 remains in a few spots in the latest Dana catalog is that its an oversight or misprint, or that some residual inventory still existed at the time of printing. Again, just speculation.

[JGVABronco78]

To make the Ford 44 data more complete, I’m going to add the older 250 stuff. These are all closed knuckle, brake drum axles. All have the same 30/19 inner/outer axle diameters as well.

67 thru 75 light-duty: #206032-3,4(67-72); #28360-1X,2X(73 thru 75)
stub #660118-1, 9.53” long
p-side inner #27656-9X, 34.94 long(overall 44.47”)
d-side inner #27656-10X, 18.81” long(overall 28.34”)
u-joint 67-72: #5-74X;
u-joint 73-75: #5-260X

69 thru 75 heavy duty: #207490-3,4
stub #3-82-411, 10.06” long
p-side inner #660178-3, 34.94 long(overall 45.00”)
d-side inner #660178-4, 18.81” long(overall 28.87”)
u-joint: #5-86X;

Note: inner shaft lengths are identical, and the HD stub is ½” longer than LD models as opposed to the 1” longer difference on the later disc brake models. If the lighter, internal type wheel hubs will fit on the HD spindles, then it appears that the LD’s could be swapped into the HD’s, or if a combo joint could be found, that an LD inner could be swapped in for an HD inner when keeping the HD outer, because the only dimensional difference is accommodations for the larger 5-86X u-joint. HD’s could not be swapped into the smaller LD housings due to interference issues obviously.

Again, the hard data in this thread was all derived form the Dana catalogs provided on the Dana Expert site found at http://www2.dana.com/expertforms/depdf.aspx?prod=AXL. The speculation is from the author of this post only.

[Nickm]

Lots of good info, it would go great here http://www.txwheelers.com/modules.ph...howpage&pid=18

But I dont feel like spendin the time right now. I might do it later


Subscribed:

[bfoster129]

Originally Posted by JGVABronco78

In the process of trying to look up alternate models to get a donor for a 76/77 HD stub, I found a lot of interesting similarities in Ford Dana 44 axle shafts. This is a compilation of axle numbers and dimensions for all open knuckled Ford Dana 44 axles from 73 to 79 except the 77 and prior Broncos which only differ from the 73 through 79 trucks in that the inner axle shafts are shorter. They use the exact same stub.
Note: each of these axle assemblies use a 1-1/4 dia. X 19 spline stub and a 1-5/16” x 30 spline inner axle shaft, and a 5-760X u-joint(formerly 5-297X).

Axle assy. #29508-1X and 2X: Found exclusively on 76/77 F-250's with full or part-time hubs according to XGI on Dana expert site.*
Stub: #37951; length 10.66”
1X, p-side #27905-35X; length 34.75(overall 45.41”)
2X, d-side #27905-31X; length 18.62(overall 29.64”)
* Anyone with a 76/77 full-time F-250 please chime in. I'd like to know if they have a normal full-time disc and cap or a bolted on external flange? If the later model wheel hubs will fit this spindle that would mean that the shorter later model stub could be used, and the donors for stubs would then be virtually limitless.

Axle assy. #660003-1,2,3,4: 1 and 2 are found in all 73 thru 78 F-100/150 regular cab, and 78 Bronco, 3 and 4 are found in 77/78 ½-ton SC, and all 77.5 thru 79 F-250.*
Stub: #620005; length 9.72
1, p-side ½ ton, 27905-3X, length 33.91(overall 43.62)
2, d-side ½ ton, 27905-4X, length 18.91(overall 28.62)
3, p-side 3/4 ton, 27905-35X, length 34.75(overall 44.47)
4, d-side 3/4 ton, 27905-31X, length 18.62(overall 28.34)
* Note: all axles use the same outer stub, the coil-spring and leaf-spring models differ by total length due to the slightly longer inner shafts. Also Bronco only uses this assembly number for the first half of 78 only, which there were other documented mid-year model changes such as headlight style. See next assembly. Also note the same inner shafts are used as 76/77.

Axle assy. #660124,1,2,3,4: same as above except stub p/n changed to 620200, found in 78.5/79 F-150, SC and Bronco. All dimensions identical to previously listed. I believe this is the cut-off point where they changed from Spicer hubs to Warn hubs, and that the snap ring groove may be slightly displaced. This would explain why some say 77 was the last year for Spicer, and others like myself say 78 was the last year, and why some models accept certain aftermarket hubs easier than others.

Axle assy. #660106,1,2,3,4: identical to prior two entries except again stub p/n has changed(#620160). Dana expert list this axle only for 79 F-150SC and 79 F-250, and identifies -1 and –2 which is an obvious misprint because the –3 and –4 are the assemblies used on the leaf-sprung. Out of 6 BOM’s for 150SC, only one used this assembly, and out of 12 BOM’s for F-250, only 2 used this assembly. The rest were 660124. My gut feeling on this was that the original intention was to keep the Spicer hubs all the way through the 79 MY for 250 and SC, but for whatever reason, at least one plant started using the Warn hubs and generated a new part number 660106. Since this is a much later catalog, 660106 was probably superceded by the 660124, which I believe is a later model series but largely identical. I'm still curious about the 106 though. My thought is that they were left in for the full-time flanges due to the spacer requiring a specific snap-ring location, but the 003 would have been much better suited for that, if my theory is correct, because the 106 would have had the groove moved for the Warn hubs. The only way this theory would hold up is if they modified the full-time spacer in 78.5 when they moved the groove, and even now neither of the 124 grooves will work, or its just an oversight or misprint. Time will tell I hope.

The hard data in this thread was all derived form the Dana catalogs provided on the Dana Expert site found at http://www2.dana.com/expertforms/depdf.aspx?prod=AXL

I broke a shaft and used your info to get a new one thanks. But i did find one typo the part numbers 27905 should be 27903. The 27905 part number doesn't exist. But my local spicer dealer figured it out.