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Old 02-12-2011, 01:32 PM   #1
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Axle question

I just came across some1 selling Dana 44 axles with 3.73 gear out of a 78 bronco front and rear for $500. Would they fit into '02 sport? If not what vehicle do I need to look for in getting some. Thanks for the help. Lilmatty

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Old 02-12-2011, 01:37 PM   #2
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Probably the wrong width and it would take a lot of work to remove the Ford style mounting brackets and weld new TJ style mounting brackets into place. Your stock front Dana 30 is ok for up to 35" tires. For the rear, I would look for a used Dana 44 out of a 1997 to 2006 Wrangler TJ for a direct bolt-in axle.

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Old 02-12-2011, 02:36 PM   #3
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Ok. Thanks. What do thoughts usually go for?
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Old 02-12-2011, 03:27 PM   #4
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Quote:
Originally Posted by lilmatty5dimes View Post
I just came across some1 selling Dana 44 axles with 3.73 gear out of a 78 bronco front and rear for $500. Would they fit into '02 sport? If not what vehicle do I need to look for in getting some. Thanks for the help. Lilmatty
Any axle will fit under your TJ...you just need to do the work necessary to make it fit. soo....welding, cutting, grinding, fabrication, etc.

A 78 Bronco will have a HP D44 with cast on wedges. You can't weld a spring perch over the cast wedge...cause its cast iron and shaped weird, so you'd need to cut it off...that means retubing the entire housing, which is a ton of work and not for the inexperienced.

The Ford 9" rear would be nice, but the bolt pattern will be 5 on 5.5, not your TJ's 5 on 4.5, and its 5" wider than your TJ.

The most common swap is a HP D30 from an XJ, and a late model Ford 8.8 from an Explorer. Other common front axles include hybrid 609s, 77-79 F250 HP D44's and 78-79 HP D60 "kingpin" front axles. Common rear axle swaps include 9's, D60's, D70s or Ford 8.8's. All require welding & fabrication except the HP D30.
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Old 02-12-2011, 04:08 PM   #5
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Want a stronger rear axle? Ford 8.8" out of an Explorer. Comes complete with disc brakes.

As for the front, truss and alloy shafts will get you everything a standard D44 front will get you, since the u-joint size is the same on both.
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Old 02-13-2011, 11:47 AM   #6
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Do you know what year explorer to look for?
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Old 02-13-2011, 02:16 PM   #7
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i belive its 96 and up
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Old 02-13-2011, 04:35 PM   #8
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i belive its 96 and up
That's about right. You should be able to get a lower-mileage axle out of a parts yard for $250-300, with 3.73 and limited slip. If you're lucky they haven't stolen the brake calipers off, if not, get some cores from the yard and swap 'em for reman.

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