axle shortening question

[1BEATK5]

im looking to build a dana 44hp for my xj. so it needs to be 60-62" wms.

i was thinking about 1980 and up wagoneer width with a ford 5 lug to match my rear axle.

i have a line on a 75 ford f150 axle. which is 67" wms.
then i would need a 80 and up wagoneer axle.

which would you do?

option 1 press the tubes from the waggy axle into the ford center, with the ford knuckles?

or

option 2 cut down the ford axle to axcept the waggy shafts?


im pretty sure i could cut down the ford axle myself, i just havent re-tubed somthing before and im not sure how easy it would be for me to do at home. option 2 seems easier. or atleast quicker with the proper tools

to answer your next question, i have a rear axle. its a 60-2. semifloat 30 spline, with 5 on 5.5 bolt pattern. its 60" wide stock

 

[big dan]

I would cut down the axle tubes to fit the waggy shafts or whatever length you need and have the shafts shortened. If you get the ford axle it might be cheaper/easier to have you shafts cut down then to find and buy a waggy front end. I think dutchman charges like $90 to shorten and respline a set of axles.

All you would need to do is grind off the inner C's and cut the axle tube off with a band saw. Then replace and weld the inner C's. If you have the tools or axcess this is much easier to do by yourself then swapping tubes.

Another plus to doing it this way is you can mount your springs and set your pinion where you want it then you can set the proper castor when you re-weld the inner C's.

 

[CUCV2]

Pretty sure a 75 Ford axle is low pinion. Just get a complete Waggy axle if you are ok with a low pinion.

When I did the HP44 for my ZJ, I used a 79 Ford F250 HP44 (.5" solid tubes, 4.10 gears) and cut it down to waggy axle width with F150 outers (5 on 5.5). Works great because the Cs will need to be rotated for the correct caster angle anyways. That said, I wish I would have just gone to 1 tons, which is what is going in there now.

 

[1BEATK5]

it seems that everybody I have talked to today thinks I should cut instead of retube. So that's probably what I will do.

Btw All f100/150 axles are hp. Only the early bronco and the highboy f250s had low.

 

[CUCV2]

it seems that everybody I have talked to today thinks I should cut instead of retube. So that's probably what I will do.

Btw All f100/150 axles are hp. Only the early bronco and the highboy f250s had low.

You might want to verify that. 77 F150 had weld on wedges, 78 and 79 had cast wedges (no thanks). The 77s are hard to find (for this reason)and usually have 3.55s. The 77-79 F250 had solid tubes that are .5" thick and can be found with 4.10s. Way rugged and easy to put your new axle brackets onto. Not sure when they started disc brakes. I think it was in 77 as well.

Another idea for you to ponder. If you use a F250 axle and keep it 8 lug and full width, you could use some H1 beadlocks to narrow the axle track. It comes out to about 3" wider than stock. Less work and a cheap set of beadlocks. Way stable for off-road too.

 

[1BEATK5]

I have verified that. The problem is 75-77 are the ones with disk brakes. 73-74 Will work but are drum. So I would need newer knuckles out to convert it to disc. My other thought was use a 78-79 because they are cheap and retune it with the waggy parts. But so far it seems easier to cut and shorten.

I don't need 1/2 inch tubes. Overkill for a 4000lb truck with a inline 6 on 35" tires. I don't want 8 lug or hummer wheels. That's just adding weight for no reason. Just a narrow hp 44. You gotta think jeep, not fullsize

 

[CUCV2]

I have verified that. The problem is 75-77 are the ones with disk brakes. 73-74 Will work but are drum. So I would need newer knuckles out to convert it to disc. My other thought was use a 78-79 because they are cheap and retune it with the waggy parts. But so far it seems easier to cut and shorten.

I don't need 1/2 inch tubes. Overkill for a 4000lb truck with a inline 6 on 35" tires. I don't want 8 lug or hummer wheels. That's just adding weight for no reason. Just a narrow hp 44. You gotta think jeep, not fullsize

Been there, done that, going bigger. That's the sickness. Good luck with yours.