Hey guys,
This is something I'm going to do and have been reading up on it. Along with what you have posted, the magazine "Off Road" by Primedia has had this as a tech project called "Project Trailrunner" on a Ranger D35 TTB in their Feb and March 2006 issues. And they're not done yet.
The TRS site said the spindles are interchangable-not the case. The write up in the magazine is OK with some pics comparing some of the parts-spindles, rotors and some of the trouble areas and how they are tackling them. One area is the alignment cams for the upper ball joint, I'm going to get one for each and design a set with the dimensionsneeded from each to work perfectly. I will have a friend machine them up on his CNC machines (probably 10 sets). These are too important to try to weld, grind and ream out by hand...as they are doing in the magazine. Hopefully the next issue has the job completed and lists all references...
A guy at the local bone yard printed out the knuckles and spindles I will be getting from him. Full size Bronco after 10/1985 and 1986-92, and F150 1986-92, of course the will be 4x4 D44 TTB setups. Quoted me $150 for the 2 knuckles, 2 spindles and they pull them. I saw some where (TRS site I think) that 1987 parts should be avoided-not sure why.
I have to be sure I research this well enough to comple the job in a weekend, because I use my truck for work driving 500-600 miles a week. So if anyone completes it and posts his/her experiences it would be greatly appreciated.