Heavy Duty Dana 44 Front Axles-the Cheap Way
By Todd Zuercher
In recent years, as four wheeling has become more extreme and tire sizes have increased, the occasional broken front axle has now become commonplace. Numerous heavy-duty replacement axle shafts have come onto the market in the past few years to address the complaints of the hardcore crowd. With the exception of those drivers who ultimately need Dana 60s to stem the carnage, these heavy-duty shafts from Moser, Warn, and others have largely solved the problem of broken u-joints and twisted stub axles. These axle shafts are made from higher-grade materials than the factory pieces, and accept a larger u-joint than stock to limit failures.
The one drawback to these aftermarket parts is price. One can easily spend $500-$600 for a typical set of aftermarket front axle shafts. Most of us like to use our rigs, but in all honesty, we're more likely to break only one or two stock shafts in our lifetime based on the type of 'wheeling we enjoy and the price tag for the premium prices is a little steep for our budgets. For those of us who like to do things less expensively and aren't as hard on our rigs, there's another option.
The stock Bronco Dana 44 front axles use a u-joint (so the axle can turn for steering) between the inner and outer axle shafts. This u-joint is commonly referred to as the "260 u-joint", in reference to its Spicer part number. The 260 u-joints have a cap diameter of 1 1/16". The heavy-duty replacement axles use a u-joint with 1 3/16" diameter caps, commonly referred to as the "297 u-joint", again in reference to its Spicer part number.
The trick is to use a factory axle shaft that uses the 297 u-joint. As long as you don't mind using Chevy parts, proceed to your nearest junkyard. What you'll want are the front axle shafts from either a Chevy ½ ton truck or Blazer made before 1977 with the Dana 44 front axle. The short side axle (passenger's side on the Chevy) is a direct replacement for the short side axle (driver's side) in your Bronco. Look at the photo to make sure the bearing surface wear area is in the same location as the bright band in the left side photo. If it's in the approximate location denoted by the finger, it's from a '77 or later Corporate axle. According to Dick at Dick's Driveshaft, the Corporate axles won't work in the Bronco Dana 44. Check to make sure the bearing surfaces (see right side photo) on the outer axle are in good shape. Pull-a-part yards usually charge about $20-$30 for this axle. For some extra insurance, replace the u-joint with a Spicer 5-297X u-joint (non-greaseable type) or equivalent before installing it in your truck. That's the cheap part.
For the Bronco's passenger side axle, you'll have to have the long Chevy inner axle shortened. Unfortunately, no one in Phoenix currently has the capability to shorten and re-spline axles. Two mail order firms that do are Currie Enterprises and Moser Engineering. The approximate cost to cut/re-spline is $50 + shipping to/from the company. If you send an axle to either company, specify a length of 27.94" from the center of the u-joint hole in the yoke to the end of the axle. A good source for the Chevy inner passenger side axles is Dick's Driveline. Dick has a whole crate of them from the Chevy Proving Grounds and will sell them for $10 each. After the shortened axle is returned, install a new 5-297X u-joint and install your new axle.
Another bonus to using the Chevy outer stub axles is they are longer than the stock Ford pieces and you can re-install that c-clip on the end of axle that you left off after your disc brake conversion; you've all converted to discs by now, right? Dick's will also sell good outer stub axles for $25 each, which is a very fair price.
Certain years of Ford pickup axles will also work. There's a debate on whether the short side needs to be shortened a bit or not. In any case, it's easier to find and use the Chevy pieces and they make more sense if you've done the Chevy disc conversion anyway.
So, there you have it…..a fairly inexpensive way to upgrade your front axles without breaking the bank. .
Sources:
Dick's Driveline
2750 E. McDowell Rd.
Phoenix, AZ 602-231-0877
Moser Engineering
(219)726-6689
www.moserengineering.com
Currie Enterprises
(714)528-6957
www.currieenterprises.com-Tightwad Todd Z.
Feel free to email with any further questions. toddz69@juno.com
