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Old 08-02-2012, 12:45 PM   #1 (permalink)
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Ford Bronco Solid Axle Swap

1990 Ford Bronco Solid Axle Swap

Dana 44 and Ford 9 axles from a 1979 Bronco were selected for this project. Being a Yukon dealer, we installed Yukon 4.88:1 ring and pinion with a Detroit locker in the rear. A custom disc brake conversion was built using stock Ford D44 front rotors and GM calipers. Settling for nothing but the best, Deaver springs were used all the way around. For simplicity, a set of James Duff control arms were purchased with the understanding they would bolt right in. Unfortunately the frame rail width was much different. It could have been forced but would have lead to premature bushing wear, so the brand new control arms were cut up. The main body of the arm was flipped for ground clearance. A custom set of coil buckets were cut on the CNC machine for a total of 6.5 lift. We were able to maintain parallel and equal length panhard/drag link so the suspension system will oscillate in unison. The panhard bar was constructed out of 1.5 x .250 DOM Tube with four strategically placed bends allowing 4.5 of up travel. Stock front driveshaft was retained with a conversion U-joint but the rear is custom.

End result: a firm, stable ride on the street and more than ample articulation on the trail.
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Old 08-14-2012, 01:39 PM   #2 (permalink)
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this was a really fun project. i dont get to work on full size rigs very often!
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Old 08-14-2012, 02:32 PM   #3 (permalink)
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Does the diff hit the TTB crossmember under the engine at stuff?
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Old 08-14-2012, 07:57 PM   #4 (permalink)
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Does the diff hit the TTB crossmember under the engine at stuff?
X2 from the looks of it that cross member needs to go on a major diet...

Looks good though
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Old 08-14-2012, 11:19 PM   #5 (permalink)
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this was a really fun project. i dont get to work on full size rigs very often!


Not the worst that we've seen. Ream the knuckles and flip the tie rod to the top. Trust me, it will help problem that you don't even know you have yet.
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Old 08-14-2012, 11:51 PM   #6 (permalink)
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Does the diff hit the TTB crossmember under the engine at stuff?
I think that is the bumstop haha. I don't see any elsewhere.
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Old 08-15-2012, 01:24 AM   #7 (permalink)
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I think that is the bumstop haha. I don't see any elsewhere.
thats what the shocks are for! they also act as limit straps.
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Old 08-15-2012, 05:33 AM   #8 (permalink)
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Looks like those arms are on upside down as well... You get better clearance if you flip them over from where you have them currently mounted. The entire length of the arm would be higher off the ground compared how your currently have them and the end doesn't matter as the tire is right there...

Looks good though - Duff looking buckets, Deaver superflex coils and Duff arms. Makes for a good combo - probably don't need to hack much out of that TTB x-member with the BGTL style lift...

Got any further shots?
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Old 08-15-2012, 07:49 AM   #9 (permalink)
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On the duff arms everything can be fabbed except for the rear C bracket, is there a vendor that offers just that piece with mount holes as shown?
Not a welded up stock one.
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Old 08-15-2012, 09:06 AM   #10 (permalink)
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Not the worst that we've seen. Ream the knuckles and flip the tie rod to the top. Trust me, it will help problem that you don't even know you have yet.
x2 on this
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Old 08-15-2012, 09:29 AM   #11 (permalink)
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The shocks are the bump stops and the limit straps....


if i flipped the tie rod to help minimize the torsional action i would have had to cut up the engine crossmember and as of right now everything clears
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Old 08-15-2012, 09:40 AM   #12 (permalink)
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Old 08-15-2012, 09:42 AM   #13 (permalink)
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Quote:
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The shocks are the bump stops and the limit straps....

Hmmm... Probably OK if the truck is just a mall cruiser...

Not so much on limit straps (not a big deal on htat suspension imo), but some bumpstops would be good idea to keep from fucking up something...
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Old 08-15-2012, 09:50 AM   #14 (permalink)
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Hmmm... Probably OK if the truck is just a mall cruiser...

Not so much on limit straps (not a big deal on htat suspension imo), but some bumpstops would be good idea to keep from fucking up something...
i will not disagree with any of this. im well aware of the disadvantages. this is a very lightly used vehicle (not that that makes it any more okay)
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Old 08-15-2012, 01:47 PM   #15 (permalink)
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All that work and you still have a D44


















































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Old 08-15-2012, 01:50 PM   #16 (permalink)
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yikes, single shear trackbar mount to boot, ouch.
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