D44 Axle Conversion Pathfinder



After running numerous AZ trails and having the usual IFS front suspension problems of broken tie rods, center links, control arm bushings, and I can't even count how many idler arms, it was time for some strength and added suspension travel.

The convering of this front end was thought out awhile before any torching ever strated. Unlike IFS Toyota's there are many companys fabricating conversion kits that are fairly simple. And Toyota did make a solid axle. There are few better candidates for a front axle swap than the Dana 44, an excellent choice for an axle swap because of its strength and availability. The D44 ring gear size is comparable to the rear H233B Nissan corporate differential, meaning that the Nissan differential is easily strong enough for this application. Both differentials were re-geared to 4.88:1 so that the ratios matched (luckily, 4.88 gears are available for both, and they help turn the larger tires). The Ford Bronco D44 housing has the differential pumpkin on the correct side for the Nissan transfer case output (left/driver side).It is nearly the same width as the original axles (in fact, a little bit narrower), so there is no need to cut them down and have custom axle shafts built. The Chevy hub and rotor assembly were added purely to replace the existing 5-bolt hub with a 6-bolt hub to allow the fitting of the same wheels front and rear. Because of the positioning of the D44, the oil pan had to be modified slightly to clear the pumpkin. This was done by slicing the sump horizontally and shifting it to the right. The exhaust had to be modified slightly to clear the driveshaft, and the crossmember had drop brackets added to increase the driveshaft clearance. The Bronco radius arms required custom brackets to mount them because the Nissan frame is wider than the original Bronco frame at that point. In order to locate the axle properly with the coil springs, a panhard rod (track bar) was added as well. The rear suspension was then fitted with Trailmaster coil spacers, track bar drop bracket, 1.5 lift coils, bump stop drop brackets, and custom made Heim jointed trailing arms.

1974 Ford early Bronco Dana 44 housing and radius arms
1978 Bronco spring mounts, saddles, and shock towers
4.88:1 ring and pinion (Dana 44 front & stock Nissan H233B rear)
Chevy K-series hub & rotor assembly disk (6 bolt)
Warn Premium locking hubs
New differential carrier
Pro Comp 3000 shocks and steering stabilizer
Heim jointed crossover steering
1/2 ton Chevy spindles
6.5 inch Superlift front coils
1.5 inch Rancho rear coils with 4" Trailmaster spring spacers
Lots of bearings, bits, and pieces

Very cool! Sounds a lot like my truck.

Have any pics? Both the original Frankenfinder idea of Early Bronco D44 and the Wagoneer Dana 44 are popular swaps.

Hey, glad you came over from CrawlinAZ to provide some tech on your Pathy. Look around...there's getting to be a lot of SAS'd Nissans out there, and a lot of them are right here on N4W.

These guys would love some pics of your truck.

http://www.crawlinaz.com/forum/album_pic.php?pic_id=228

http://www.crawlinaz.com/forum/album_pic.php?pic_id=219

Welcome! Nice Pathy. You will love the Dana 44.

Nice rig. I've always liked the 2 door Pathys.