TTB info & year differences

[philofab]

Here is some general info about our front ends and year differences for spares and getting the strongest part.

Our Dana 44s are reverse rotation hi-pinion.
Most are a 3.50 gear from the factory.
A new carrier is needed for gears lower (numerically higher) than 3.92

Gear carriers:

Type 1: 80-82 gear carriers used a bolt on axle retainer, used different bearings and seals than 2 & 3
Type 2: 82-92 gear carriers used a c-clip to retain the axle, used different bearings and seals than 1 & 3
Type 3: 93-96 gear carriers used a c-clip to retain the axle, used different bearings and seals than 1 & 2

Knuckles

80-85 Knuckles have bolt on calipers and 6 bolts holding the spindle to knuckle. I consider these strongest.
1993 Knuckles have tension pin style calipers and 5 bolts holding the spindle to knuckle.
87-92 Knuckles have tension pin style calipers and 6 bolts holding the spindle to knuckle.
94-96 Knuckles have two bolt style calipers and 6 bolts holding the spindle to knuckle. Also have ABS provision.

Spindles

80-92 Spindles are six bolt and the same except for 87 with "top hat"
93-96 Non-abs is 5 bolt without a notch
93-96 ABS is 5 bolt with two notches


Rotors

Type 1: 80-93 but NOT 1987
Type 2: 1987
Type 3: 94-96

Brake pads

Type 1: 80-86
Type 2: 87-93
Type 3: 94-96

Axles

80-96 Outers are all the same unless it's a 87 with top hat style hubs
80-96 LH inners are all the same
80-82 RH centers are different to accommodate bolt on centers.
83-96 RH centers are all the same
80-83 slip yokes are 5.5 inches
84-96 slip yokes are 5.06 inches

Hubs

Interchangeable with some Dodge, Jeep, Chevy, and other Fords with D44 axles.
1987 had "Top Hat" style hubs which made servicing bearing much easier but are oddball. 87 used different outer axles.
Five bolt auto hubs can be switched to manual hubs with any factory or aftermarket hub.
Three bolt hubs need a kit to be switched to manual

Housings are all the same

Passenger (short) housings bend often. I have seen many trucks with a Ford part department sticker indicating replacement. This housing is much stronger if it is plated in on the open side between the bushing and axle hole. Axle hole normally needs porting on bottom for axle clearance on C&T LT applications.

Ball joints are all interchangeable

Napa ball joints with blue boot are very strong, so are Spicers

[gunit]

Great job Philo, this needs to be stickied.

[Nick]

Great info Philo, thanks!

[Phoenix0783]

Gear carriers:

Type 1: 80-82 gear carriers used a bolt on axle retainer, used different bearings and seals than 2 & 3
Type 2: 82-92 gear carriers used a c-clip to retain the axle, used different bearings and seals than 1 & 3
Type 3: 93-96 gear carriers used a c-clip to retain the axle, used different bearings and seals than 1 & 2

What's different about the bearings? I'm getting ready to swap gears in mine and was just curious.

[philofab]

Gear carriers:

Type 1: 80-82 gear carriers used a bolt on axle retainer, used different bearings and seals than 2 & 3
Type 2: 82-92 gear carriers used a c-clip to retain the axle, used different bearings and seals than 1 & 3
Type 3: 93-96 gear carriers used a c-clip to retain the axle, used different bearings and seals than 1 & 2

What's different about the bearings? I'm getting ready to swap gears in mine and was just curious.

Just swapping gears should not present any problems with bearings. The seals and bearings I am referring to are for the axles.

80-82 Bolt on centers used a different axle bearing and seal on the right (passenger) side than the later 83-96.

The left seal is the same between 80-96.

Pinion seals are the same on 71-96 Dana 44s

Inner & outer pinion bearings are the same 80-96

Carrier bearings are the same on all Dana 44s.

[Phoenix0783]

Gotcha, thanks!

[shockseals.com]

Did any broncos come with a front limited slip factory?

My rear tag says 3.73.

Going to 4.56...front will need a new carrier accoridng to above. Why is that?

[philofab]

Did any broncos come with a front limited slip factory?

My rear tag says 3.73.

Going to 4.56...front will need a new carrier accoridng to above. Why is that?

Some did have a factory limited slip.

The carrier break is at 3.93 or so and is required due to pinion size being larger with lower gears. Because of the larger pinion the ring gear is offset farther away.

[shockseals.com]

Is there a way to know before tearing into it if the front is LS? Vin? Tag? If it is LSD...does the carrier still need to be swapped?

[philofab]

Is there a way to know before tearing into it if the front is LS? Vin? Tag? If it is LSD...does the carrier still need to be swapped?

The front tag will have a L between the first gear ratio number and the last two. Like this: 3L73 rather than 3 73. It would still have to be swapped out even if it's a LSD. You can also jack the front end up so both tires are off the ground and spin one tire by hand. If the other spins the same way it is most likely posi, if it spins opposite it is open.

[Polarcub]

Thanks for all the info Philo concurr this needs to be stickied