1995 Ford F150 DD prelander

[85Yota]

Ok got rear 3rd all regeared with 4.86 gears. Rpm is much better for all around driving with the 35s. 0 noise. Just drained the 85w-140 so ill use that in the front diff. No metal or anything in the rear gear oil and all was good looking through fill plug.

Had a king snake come inspect my work in the shop, he was happy with the work so I carried him back outside in the bushes.

 

[85Yota]

Now I had 4.86 rear gears done, I went out to the more race and truck worked awesome.
Now I need to match the front gears.
Installed some 4.88 gears in the front and it all setup great. Im very happy I biught the vevor carrier bearing puller or I wouldn't have been able to do this diff with having to pull bearings to install shims to adjust backlash and pinion depth.
While I had it apart I noticed the middle u joint yoke had some small gouges and I saw one cap was sticking out about 1/8" more than the others. Looking why it was like that I noticed the cap inner snap rings groove was broken off and internal snap rings that hold i joint in was broken. So I got a new u joint and tore that one apart. Once I got the joint out I noticed that ear was slightly bent as well.

So now that the axle is damaged i figured perfect time for me to upgrade that joint ti run the D50 inner axle with the larger 1350 u joints. I also installed a tok woods offset u joint so I can keep the max 18" travel with stock width and everything works as it should with no binding

So to run the D50 shaft you need to machine the shaft between the spline and axle bearing since it interfere with the d44 diff and doesn't let the axle go in fully. Also the end of the axle past the snap rings groove is about 1/8" longer and hits the centerpin keeping it from fully going in so snap rings can be installed to keep the axle in place.

Now reassemble the entire front end. Helpful hint when reassembling the D44 front diff install a short 3" piece of all thread into 2 of the holes so you can. Slide those into the beam to slide it in straight so your silicone doesn't get smashed wrong and will seal up fully. Got that all in and installed new 12pt bolts, because race truck, and painted the fill plug gold to match as well.

 

[Tree trunk]

Really good stuff here, thank you for the write up, I will give this a shot when the diff comes out for a little investigation on the mystery noise coming from the diff or transfer case.

When I was doing the gears in the bronco I was told the 4.88’s are prone to failure because of the small pinion size.

I’m interested in your opinion on that…

 

[85Yota]

my friend has big hp ls stroker with 5,13 and no problems. i dont rock crawl so not worried about strength of the gears

 

[85Yota]

Yeah doing the 3" long studs with all thread worls great. I used the top holes so I could lift line them up then slide it in. I then snuggled up 2 bolts, installed side bolts and unscrewed the studs and installed all the rest of the bolts. Then installed axles and filled with gear oil. I also like the 12pt bolts and they look full race and are pretty cheap on allens fasteners. They're also nice if doing a truss with a bolt inside a tube since you can use smaller bolt because smaller socket fits inside smaller tubing.

https://www.allensfasteners.com/sea...chParamTxt=0091A&btnSearch.x=85&btnSearch.y=4

 

[Tree trunk]

Okay nice

Such a cool build by the way!!

 

[DesertGoat]

excuse me, an offset what now?

is that also a solution for the D44 stuff on that inner axle joint that has to be ground out usually?

 

[85Yota]

Yes BUT it only works with the 1350 u-joint which would be a D50 inner axle/slip.

https://4xshaft.com/products/super-...o_g3ejS5OgabIa-zhZiSSSVrkn7SrdkD4Ot49ovHM9vg0

The D44 stuff has the smaller 377 internal snap ring joints and nobody makes an offset joint for them.

 

[FasterNU]

^^^ Did i just notice that you tack welded all the ring gear bolts onto the spool??

 

[Tree trunk]

Also… are you spooled up front?

 

[85Yota]

Open carrier up front just had to change it to the right one for 4.88 gears.

Yes I tack welded all the ring gear bolts on the rear 3rd. I know a few people who have had to do that on the ring gear bolts and the carrier bolts, specifically on the Ford 10.25 rear axles, which like to come loose more often.