Axles keep breaking

[BKennedy]

I have had an ARB in my Dana 35 with 35" tires for about ten years now and have not had any breakage. But, then again, I am also not trying to break it. If you have a habit of bouncing the front end off the ground while on the throttle, you just need to accept the fact that you are going to break stuff.
However, I do like the Dana 60 girl idea.:

 

[whitetrashfab]

http://explorerforum.com/forums/showthread.php?t=282624&page=2

#38

some of my problem...

I know people that ran 37's on a dana 28 without a problem... I also worked out at a mine that had at least 30 or more superdutty's for light dutty trucks and broken axle parts were part of life with 31's in those conditions. Its all about how you drive and what you want to do with the truck. I like to be the "watch this guy" so I expect things to fail.

 

[SVO42]

The dana 60 has a 69.25 WMS, my early bronco dana 44 has a 59.25 wms. Our trails here in WA are narrow and I want to keep my tires under my rig so I cut my axles down to match what I already have. The Forrest Service is trying to make 80"s outside to outside of the tire the "legal" size so Im just trying to build within our stupid rules. You can stay under 80 with offset rims like Hummer ones but you will run into steering/radius arm problems in a hurry. The only "big" reason why the 78'-79' fronts are so popular is the diff offset alows you to mount your radius arms or leaf springs farther inboard alowing you more steering and rim options. You can make the newer dana 60's work with radius arms with a little cutting like Im doing.

http://explorerforum.com/forums/showthread.php?t=304600

Using stock length shafts the narrowest D60 you can do is a hybrid early model Ford D60 (78/79) and a later model 60 (87+). Get a late model D60 and cut the passenger side tube down to fit an early 60 shaft. Handy chart: http://www.alloyusa.com/gm-ford-dana-front-axle-kits.html. Then you can use wheels with more backspacing to tuck them in more but be sure to check clearances with brake parts and knuckles.

 

[whitetrashfab]

I will have Dutchman cut down my stock long side shaft for $50 or buy a set of chromoly axles from Nitro. JT diff. wants an extra $43 for making the long side 10" shorter to fit my axle if I buy the hole set up from them with 35 spline stubs.

 

[bigbzc]

You could get it from this one: http://www.nc4x4.com/forums/showthread.php?t=105267&highlight=explorer

He's decided to part it.

Do you go to Gulches often?

Actually I plan to get it back together and take it to Gulches for the first time on Feb 19th. Gonna be a big event with alot of people. It's the "Save The Gulches Ride" Hope to see you there, look for Club 4x4 Upstate SC and you'll find me lol (and a hell of alot others)

 

[LBarr2002]

Actually I plan to get it back together and take it to Gulches for the first time on Feb 19th. Gonna be a big event with alot of people. It's the "Save The Gulches Ride" Hope to see you there, look for Club 4x4 Upstate SC and you'll find me lol (and a hell of alot others)

I'll be there with Mid Carolina Jeepers and Clemson Offroad. I've wheeled with a couple of the Club 4x4 Upstate people before.

 

[bigbzc]

I'll be there with Mid Carolina Jeepers and Clemson Offroad. I've wheeled with a couple of the Club 4x4 Upstate people before.

Efin A man. Look for the Twin Explorers. Me and my bud Toby both have white X's. We'll be there Sat and gonna spend the night and do some real wheeling Sunday after the croud clears. Gonna be alot of people Saturday so we just plan to take it easy and watch. Hope to see you there

 

[zukman]

there is a thread on pirate4x4, where someone is making a setup for a d44, where as, you can use all the stuff out of a d50, f250, and use 35 spline axels. best of both worlds, small,lite, and strong.

 

[SVO42]

there is a thread on pirate4x4, where someone is making a setup for a d44, where as, you can use all the stuff out of a d50, f250, and use 35 spline axels. best of both worlds, small,lite, and strong.

"Jana" 76 and 54 big thread: http://www.pirate4x4.com/forum/showthread.php?t=914583

Jana 76: http://www.pirate4x4.com/forum/showthread.php?t=946421

Jana 54: http://www.pirate4x4.com/forum/showthread.php?t=948996

The 76 is a 60 housing with a 70 gearset. The 54 is a 44 housing with a 50 gearset. And, before you ask, no, according to the guy a "65" (or whatever you'd call it), a 60 gearset in a 50 housing can't be done, which is a shame since Dana 50s can be had for a song.

 

[bigbzc]

"Jana" 76 and 54 big thread: http://www.pirate4x4.com/forum/showthread.php?t=914583

Jana 76: http://www.pirate4x4.com/forum/showthread.php?t=946421

Jana 54: http://www.pirate4x4.com/forum/showthread.php?t=948996

The 76 is a 60 housing with a 70 gearset. The 54 is a 44 housing with a 50 gearset. And, before you ask, no, according to the guy a "65" (or whatever you'd call it), a 60 gearset in a 50 housing can't be done, which is a shame since Dana 50s can be had for a song.

That sucks cuz I can sing pretty good lol

 

[LBarr2002]

So was it you or your friend that rolled? And where are the pictures?

 

[bigbzc]

It was me. My friend had his baby that week so couldn't go. I didn't get to take many pics but others did just don't know where they posted them.

Here are some after shots. I cut the roof off and will put in a roll cage this summer.