RBV Axle Upgrades, Add more beef to your 4x4 (or 2WD rear)

[compleckz]

Originally posted by '4x4junkie' date='Jun 21 2006, 02:25 AM'
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Strength & reliability:

• Automatic to Manual Locking Hub Swap ('83-'97 w/TTB suspension)
  Manual hub "conversion kit (much cheaper than kits sold specifically for this purpose)
  
  
• Keeping those 'loose' hubs secured to the rotors
  
  
• Fix your '98-'00 PVH 4WD hubs for good:
  Permanently lock them engaged (cheapest fix)
  Convert to the later Live Spindle setup (strongest fix)
  AVM Manual Hub Upgrade (most practical fix)
  
  
• Swap out the weak '83-'89 Dana28 front axle for the stronger '90-'97 HP Dana35
  
  
• Beefier manual hubs for your front Dana35 (No more flying hub parts)
  
  
• Beefier u-joint upgrade for your Dana35 axle shafts
  
  
• Alloy stub axle shaft for the D35 (upgrades the weakest part of the D35 shaft, gives about a 5-10% overall strength increase... Worthwhile if you've already broken or are replacing this part for another reason)
  
  
• D35 Circlip Eliminator Mod (eliminates having to remove the diff to take out the passengerside axle, also allows the use of certain lockers)
  
  Internal Spring
  External Spring
  
  
  
• D44 Knuckle Swap for the D35 (gives you bigger brake rotors, and wheelbearings that are more rugged)
  
  
  
• Swap in the strength of a 31-spline rear axle:
  Explorer 8.8" axle into a Ranger
  If you get lucky enough to find an FX4 (Level-II) 8.8" axle
  
  
• Cure the vibrating two-piece driveshaft on your lifted Supercab truck

Useful information:

• Identifying what front axle you have:
  http://www.therangerstation.com/tech_library/dana_28_35.shtml (1983-1997)
  http://www.therangerstation.com/tech_library/dana_35_sla.shtml (1998-2011)
  
  
• Identifying what rear axle (& gear ratio) you have:
  http://www.therangerstation.com/tech_library/axle_codes.shtml
  
  Further info:
  http://www.therangerstation.com/tech_library/Ford-7_5-axle.shtml (7.5" axle)
  http://www.therangerstation.com/tech_library/Ford-8_8-axle.shtml (8.8" axle)
  
  
• What is a "locker", "Posi", "limited slip" or "open" differential?
  
  
• Overview of specific lockers

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Axle gear ratio recommendations for bigger tires:

These ratios will provide the best balance between power and fuel economy. Do not fear the gear, MPG has often been found to be better in many cases vs. when running gears taller than what's listed here (especially with the 2.9L engine).

• ALL RBV engines EXCEPT 4.0L V6:
  29" tires = 4.10
  31" tires = 4.56*
  33" tires = 4.88**
  35" tires = 5.13*
  
  
  
  
• 4.0L V6 engine:
  29" tires = 3.73
  31" tires = 4.10
  33" tires = 4.56
  35" tires = 4.88
  37" tires = 5.13

For very early Rangers without overdrive transmission:
Use 4.0L chart


* Not available for Dana28 axle, see Dana28 to Dana35 swap article above.
**Not available for Dana28 & 7.5", See above for 8.8" swap options.

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