well. See....hmmmm
let's clear the plate. I'm seriously thinking about doing this. Reason being, I can get a complete Dana 44 TTB setup for $40. Now that I've got that out...
-I'd like to bolt the beams in the stock pivots. I'd need to trim like, what, 1/2" to 1" off the middle shaft where it goes into the diff, and where else? I'd do an c-clip eliminator (spring), so that won't be an issue.
Trim the big spline on the passengerside main shaft and/or the spline on the passenger inner shaft (WATCH that you don't trim so much off the inner shaft that the seal doesn't sit on the smooth machined part of the shaft anymore!)
-I plan on getting the steering linkage as well. Now, I'd probably need to trim a bit off each end of the linkage where the TRE adjustment collar is, correct? like, another 1/2" to 1"?
-speaking of steering, what are the odds the fullsize linkage will bolt to the RBV pitman arm?
I would imagine so, yes. You'll probably want to check things before you cut it at all though. If the relationship of the steeringbox vs. the axle is different on the RBV frame vs. the F-150, you probably won't need to trim one side at all, but have to trim more on the other (or it might not even work, I wish I could tell you for sure, but I'd need to get an F-150 in front of me to take measurements from, and I don't have one accessible)
TRE at the pitman arm is same for F-150 vs. RBV (Its the same pitman arm)
-Does the Dana 44 TTB have the same sized u-joint as an RBV front driveshaft? or should I get a custom shaft made, with an RBV t-case end and a D44 TTB end?
No, the u-joint is bigger.
You can either get a conversion u-joint,
Get a different yoke for the axle (1310), or
Have the weird driveshaft made
(I would get the yoke if you're changing gear ratios on it)
-you said brake lines bolt up. check. Did you mean the D44 flexhoses bolt to the RBV hardlines, or that the RBV flexhoses bolt to the D44?
RBV flex hoses bolt to the D44 calipers.
-Should i use the D44 radius arms or RBV arms? I plan on extending them anyway...(i'll be lifting the truck whenever I install it)
You can use either on the D44, although the RBV arms are a tad wider and would need a spacer (washer) between one mounting ear of the arm and the axle.
-I'm hoping to have around 4" of lift, using f250 shock mounts, longer shocks, the aforementioned extended arms, etc. What type of coils would you recommend? EB? XJ/TJ?
Is this all going on the BII in your sig? What do you figure the weight will end up being?
Most likely I would say use some flexy coils for an early Bronco, or Skyjacker brand XJ coils (or any ZJ coils).