My 1996 Ford Ranger 4x4 (TRS-2) Re-Build

[dvdswan]

Ok, miss informed my brain. Here's what I read...
Dana 35 VS Dana 44: The weak link in the Dana 35 TTB is generally in the flange style locking hubs. However, the Dana 35 TTB actually shares the same axle shaft diameters and u-joints as the Dana 44 TTB. Their has been many people that have swapped out a Dana 35 TTB for a Dana 44 solid front axle out of a Ford Bronco. Some people have chosen to swap out the Dana 35 steering knuckles and replace them with Dana 44 knuckles to gain the stronger Dana 44 locking hubs.

So my next thought is dealing with fab skills... Couldn't you just cut-out the D44 chunk from the TTB and weld it into the D35 TTB?

I guess its thinking outside the box but I'm sure I'm not the first.

 

[85_Ranger4x4]

Great read and info. But I though I read on the site somewhere that you could put the d44 carrier in the d35 housing. Is this correct or did I read that wrong?

You can do 44 knuckles (brakes/hubs) with a little work.

Negatory on swapping carriers.

 

[Curious Hound]

Couldn't you just cut-out the D44 chunk from the TTB and weld it into the D35 TTB?

If you're saying what I think you're saying. The "chunk" is bolted to the axle beam. I doubt that the D44 would fit and bolt into the D35 axle beam. By the time you're trying that and swapping knuckles and stuff, you might as well use the whole D44 assembly as-is.

 

[dvdswan]

You can do 44 knuckles (brakes/hubs) with a little work.

Negatory on swapping carriers.

Guessing I didn't elaborate that. I meant cutting out the D44 section for the chunk and welding it into the D35 axle?

 

[dvdswan]

I guess its all on ones perspective. Modifying parts on the frame vs. modifying the axle housing.

The d35 axle shafts are the same size (diam.) as the d44. are they the same spline count? because if they are you could use those in the d44 carrier.

Again, thinking outside the box.



edit: ok so I'm totally reading everything wrong. You would still need to modify axle shafts as they are not the same size.

 

[Jim Oaks]

The Dana 35 TTB and Dana 44 TTB use the same size u-joints, but the axle shaft diameters and splines are different:

Dana 35 TTB: 1.16-inch shaft with 27-splines
Dana 44 TTB: 1.31-inch shaft with 30-splines

By comparison a Dana 60 is a 1.50-inch spline shaft with 35-splines.

At the moment I can't think of anyone that's busted a carrier or shaft running 35's on a Dana 35 TTB. I've seen some locking hubs explode though.

I know that @4x4junkie did a Dana 44 TTB swap a long time ago, and I believe his opinion now is that he'd just do the knuckle and hub swap on a Dana 35 TTB.

 

[85_Ranger4x4]

If you go by the book a D35 uses a weaker u-joint cross than a 44 but the 44 cross is a direct fit upgrade.

I think it is usually a u-joint related issue tearing up the yokes that "ruins" a shaft. Especially with a locker.

Lots of tips and tweaks HERE, most are pretty cheap and simple to do.

 

[dvdswan]

Well, @Jim Oaks, if you don't plan on rock bouncing I really wouldn't invest in the D60 then. Big thing on the hubs snapping on the D35, they're the weak point, correct. Doing the D44 knuckles, will they still be the weak point?

 

[dvdswan]

If you go by the book a D35 uses a weaker u-joint cross than a 44 but the 44 cross is a direct fit upgrade.

I think it is usually a u-joint related issue tearing up the yokes that "ruins" a shaft. Especially with a locker.

Lots of tips and tweaks HERE, most are pretty cheap and simple to do.

I've been reading lots of items on there. One thing I've learned is the TTB axle is actually really good. Just word of mouth has trash talked them. The only thing I dislike about them is if you lift up the front end by the frame it looks like they got kicked in the jewels. LOL

 

[Jim Oaks]

View attachment 57077

Shit. ​

So in March I was getting a check engine light and P1445 error code.

Today I jump started the Ranger, it was dead from sitting for a long time, and I didn't get an engine light. I drove it and it seems to drive fine. I'm puzzled because I was going to try and figure out the P1445 code, and it disappeared.

 

[dvdswan]

The battery could have been dead enough to clear the code. I would image that it will come back.

edit: did you have to reset your radio stations?

 

[Jim Oaks]

I did. Battery was definitely dead. I figured that was a code that was going to show up right away though.

 

[bobbywalter]

It will come back.


The carriers fail with high power when locked with a d35 when abused to the point of shaft failure.

One or two shafts frags them.

 

[Jim Oaks]

Shit

 

[Jim Oaks]

Honestly, I wonder if I should even care if the code comes back if I can still drive it? I just want it to get me through another Round-Up.