D44 to D35 TTB outer swap, real info finally.

[Byrd91]

I just got this info off another thread so I thought I'd give it its own for search purposes. I know there has been a lot of curiousity on this topic, so here it is.

I did the 44 swap on the TTB a couple years ago. The first thing I noticed is the brakes don't feel good. As far as the actual bolt up, the balljoints are different where they go in the steering knuckle. Ex's were smaller outer diameter. I took a piece of steel (not sure the thickness now) and cut strips to fit around the outside of the balljoint from the Ex, then fitted them into the hole in the 44 knuckle and spot welded them in place. You'l want to make the strips narrow enough they don't cover the lockring groove in the 'joint. Then I used a wheel cylinder hone and honed the shims out until the Ex 'joints were about the same press in fit as in the original knuckles. This set-up worked well and didn't get loose over time.Another thing I did was the lower joint rubbed the u-joint after assembly making a clicking noise. I removed the hub,spindle and axle, ground the top of the balljoint down to the nut and reassembled it. No more contact. As far as finished mods, it got rid of that front end shake and seemed to handle better,but the brakes were odd feeling due to the larger caliper on the smaller Ex master cylinder. Alignment and front to rear track was unaffected and I got a set of locking hubs to boot. I bought a whole rolling F-150 chassis for 200$ and swapped everything from that. You'll need all parts fromm the ball joint out including the axle stub. the Ex's tie rod ends fit the 44 steering and the u-joints were the same dimensions and fit the same. I would put a F-150 master cylinder on if I did this mod again.

 

[410Fortune]

Byrd,

What about the bolt pattern? You used the D44 spindle, rotor, caliper, and hub correct?

Would it be easier/possible just to machine the D35 beams to accept the D44 balljoints? Or to use the D35 ball joints inthe D44 knuckle?

I understand what you did to make it work I just want some clarification
I assume the work done to the shims and ball joints was done to the D44 ball joints correct?

 

[410Fortune]

ALSO:

According to therangerstation.com the D44 spindle will bolt up to the D35 knuckle. Is this true?

If so then couldnt you just replace the outer axle shafts with the longer D44 units at the U joints.

Bolt on the D44 spindle
then use the D44 rotor, bearings, spindle nuts, and hub?
Would this work with the D35 caliper??

 

[rocklaurence]

Great to hear that its been done. I agree with 410. I would have thought that opening up the alignment cam and the tapered hole in the axle would have been easier. Id like to do it and then use the Auto hubs with the 44.

 

[RVZII]

Best I Could Do

Yeah, opening up the holes woulda been easier, but I was afraid of weakening the piece. The way I did it modified or changed nothing from its original form. I just shimed the 44 knuckles to tightly hold the 35 balljoint. Yess I used the 44 outer axle stubs, steering knuckles, spindles, hubs, etc. Only difference was in the size of the balljoint outer diameter. The worst problem I had was the axle stub must ride slightly lower in the spindlle because both axle joints hit the top of the lower balljointd a slight mark across the caps and yoke of the u-joint. No, the 44 spindle does not bolt to the 35 knuckle. The 44 spindle flange and bolt pattern is a little larger. If I had a way to post pics I'd take photo's and post'em. Trust me, I did the mod. I wouldn't have gone to all that trouble if it was as simple as changing spindles.

 

[rocklaurence]

RVII, how did you mount the tie rods? Did you use the Explorer rods and did you mount them under (as on the D44) or over (as on the D35) the mounting arms on the knuckles? Did you use spacer rings to change the bolt pattern on the rear? Sorry for sooo many questions.

 

[Trckmagik]

Bump. Do you have any photos of what you did yet? Myself and one other member are doing this swap right now and would like any info you have for us. Thanks for the info above.