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Old 01-25-2006, 08:05 PM   #1 (permalink)
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Dana 44 ring/pinion swap

(Posted in the trucks section but no replies.) I'm looking to replace the 3.50 gears in the Dana 44 front end of my 1974 bronco. My first question is:

Will a 4.09:1 carrier and ring/pinion from a 1976 ford F250 (30 spline) bolt in?

Secondly, is this something I can do in my garage? I've heard I need a press and other special tools. If the gears have already been mated can I assume these will already mesh well? In reading my shop manual I think it says I need to split my case!?

Any other considerations? Thanks.
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Old 01-26-2006, 07:51 AM   #2 (permalink)
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Dana 44 ring/pinion swap

If the carrier is a Dana44 you SHOULD be ok.

As for installing them, since you're going to a different housing you'll need to re-shim. Replace all the bearings!

If you've never done this, pay someone to do it (typically run you $100 if you can find a good shadetree mech). If you're only driving the thing on the trail, you could get away with doing it yourself, so long as you won't mind buying everything new and starting over when it fails (that's if you don't get it right).
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Old 01-26-2006, 08:31 AM   #3 (permalink)
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Dana 44 ring/pinion swap

You'll definitely need to recheck pinion depth and wear pattern to get the shims right for the new housing. The "case splitter" is a device that bolts to the diff cover area and applies pressure towards the hub, stretching the case a couple thousandths so you can install the diff and shims without getting out the BFH and ruining the bearings. As dirtball said this is something that should definitely be done at a shop, and won't cost much compared to the headache you will avoid.
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Old 01-26-2006, 10:03 AM   #4 (permalink)
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Dana 44 ring/pinion swap

This sounds like a bigger project than I hope to take on...

The estimates I am getting are around $450 in labor (plus bearings, other parts) to do this if I supply a carrier and ring/pinion. I'm still looking for the shade-tree mechanic who will do it for less
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