Looking for Help in PNW: D44 Swap and 8.8 Rebuild

[bnbader]

Hi Everyone,

Its been a while since I completed my last build on my 92 Explorer and the 8.8 finally gave out. I'm thinking about doing the long awaited D44 straight axle swap in the front and a full rebuild of the 8.8 plus upgrade the suspension while I'm at it. I did the original lift by myself but I no longer have the time to wrench so looking for someone with experience who'd like to take on the project in the Pacific Northwest.

What I'm thinking:
1. Rebuild the 8.8 diff with 4.56 or 4.88 gears using these parts. It currently has 4.56 gears and ARB Air Locker (working on warrantying some of the ****ed parts..):
https://www.amazon.com/gp/product/B0078U9CT0/ref=ox_sc_act_title_4?smid=A1C04IHUSEWFPP&psc=1

While at it, do a disk brake conversion as the rebuild kit extends the axle out by 1" on each side and requires the disk brakes. Can probably do it for cheaper than the cost of the below kit but not sure? Open to suggestions.

https://dufftuff.com/product-category/explorer/explorer-brakes/

2. Do a straight axle swap replacing the Dana 35 TTB setup with a Dana 44 utilizing a kit and adding an ARB locker to the front. The ARB air compressor is already there. I received a suggestion to use a swap kit from Giant Motorsports or James Duff but I'm open to suggestions.

https://dufftuff.com/product-category/explorer/explorer-solid-axle-swap/

4 Wheel Drive Beam Kit – Giant Motor Sports

www.giantmotorsports.com

3. Redo the front and rear suspension setup to accommodate bigger shocks and leaf spring packs (my current setup is undersized) so redo the leaf's (for the third time) and get bigger shocks to get a roughly 5.5-6" lift able to accommodate 35-37" tires. Potentially do some shackles etc. Not 100% sure what it would look like in the end but would need to work with the new diff setups and be much more robust.

4. Install a Bronco II gas tank where the spare tire used to go for an extended range fuel setup. Would be open to ideas on whether to run two fuel pumps and a switch etc... I believe this is the one that fits..?

https://www.summitracing.com/parts/...kUvp-Ftms7m1dExAO7_CBXz4WJnL8QzxoCSrUQAvD_BwE

5. Any other general maintenance or items needed to make sure this project is successful.

Thank you for the help and please DM if you can assist or want to take on the project.

Ben

 

[dvdswan]

Are you actually in Seattle area? Or just the Sound?

 

[bnbader]

Are you actually in Seattle area? Or just the Sound?

In Seattle.

 

[Fix4Dirt]

in the PNW @410Fortune is your guy!

 

[bnbader]

@410Fortune would enjoy connecting. Feel free to DM me your info. Thanks!

 

[410Fortune]

Why a solid axle swap kit? I mean the James diff stuff is super nice but I don’t think you need an”kit” to go from ttb to monobeam
The ol ford radius arm Dana 44 with wedges fits under there so easily! And if you wrist the passenger side arm you get mad articulation even with just coil springs… don’t have to go crazy with a 12” stroke coilover or anything. Keep it simple!

Can put gen ii axle under it or just add disc brakes to yours, my friend Brett wrote an article about swapping the gen i rear drums for discs about 25 years ago right here on this forum… again stock parts work fine keep it simple and cheaper

Can change the master cylinder to f150
Unit to match the new front Dana 44 larger brakes and new rear discs or can go full hydroboost

Rear suspension can swap in some
Chevy 64” leafs get some nice arched ones for the lift and some flex, a good simple shackle and shock setup and the rear end will flex enough to keep up with the wristed arm Dana 44 front.

Bronco ii fuel tank is a great idea, 32’gallons center mounted easy access panel to the fuel Pump through the hatch floor. Are you keeping the stock side saddle tank as well for almost 50
Gallon capacity or does the stock tank go away?

Stuff 37’s on a sploder takes a little work they like to get into the hvac box and firewall, without lifting the body to the sky we wouldn’t to push the front axle forward asMuch as possible
I vote 4.88 for gears with the v6 and 36-37”‘tires maybe even 5.13 depending on your use and trans

Sounds like a solid plan! Would be late this year next spring before
My shop would be ready for a project like this… I have current commitments I must complete first!

 

[bnbader]

Sounds great @410Fortune I'd enjoy talking about your ideas on the phone. Those kits are very pricey so anything we can do to reduce the cost is greatly appreciated. In terms of timeline, I'd ideally like to get the project done by next spring so its ready for the 2025 summer season to enjoy.