FULL-WIDTH AXLE SWAP
UPDATE: Plans have changed drastically. The Chevy 1/2-ton axles have been put up for another project, and instead, Im using a set of Dodge 3/4-ton axles. That is a D44HD and D60FF with 4.10 gears.
After busting the pinion on my FJ-40 axle, Ive decided it was about time I built a set of full-size axles.
I traded a $180 Chevy 350 rebuild kit for a Dana 44/Corp 12-bolt combo from a 76 Chevy K10. I started by buying a 5.14:1 gearset for the rear. What I didnt know was the fact that it was for a GM CAR 12-bolt. Richmond gear gave me a part number for the conversion pinion bearing to make it fit, but I never was able to get the pinion depth right.
I decided since I was going to have to buy a new gearset for the rear, I would get a Corp 14-bolt, or Dana 60 rear. When out looking for a rear-end, I found an old 73-ish Dodge 3/4-ton. So, I killed 2 birds with one stone, and decided to just go ahead and get both axles.
The front axle was a Dana 44HD with drum brakes, manual locking hubs, and 4.09 gears. The rear was a Dana 60FF with 4.10 gears.
To accomodate for the extra width of the distance between the front spring perches, I cut off the stock front bumper and added a piece of 1/4" wall 3.5" square tubing in its place. And for the rear leaf spring hangers, I welded some 5" long pieces of square tubing onto the side of the frame and welded the hangers to them.
This put the front axle about 4" forward of its stock location.
As for the rear, some extra-long spring perches were welded to the axle with the centering pin holes all the way to the front.
All this brought the wheelbase to 99" keeping the rear tires just barely in front of the rear bumper...
LEFT: This is a picture of it with the 37x12.5's on stocker steel wheels mounted on the front.
RIGHT: The old steel wheels were tossed when I came across a great deal on some American Racing 16.5x9.75 aluminum slotted mags.
Notice the difference?
Standing sorta in front of my Patrol is my fiance. No, its not really all that tall. She is only 4'11". Not to mention she was only wearing flip-flops.
Also, the rear fenders required trimming. I could barely squeeze my finger between the bottom of the fender and the top of the tire, EDGEWISE!!
Ahhh... much better. I cut the fenders out at about 9:00pm in January. My mother's neighbor was P.O.'ed!! Oh well...
Nice view of the front passenger side fender. Looks tons better, eh?
Rear view. Still need to fix those rear doors, add tail lights, etc.
It is nearing completion. All thats left to make it drive is fabrication of the front driveshaft, addition of new custom fuel tank, and other little bitty details. Check back soon for more pics.
Heres some new updated pics:
My new fuel tank. Im not sure what it came out of, but it was sitting in the back of an 80's model Chevy 1/2-ton.
The top is off again, at last!
The roll cage build-up. I had to weld pieces together due to the fact that I could not get anybody to bend up pieces of tubing for a "roll cage" I had to lie to them and say it was for a "railing" for liability purposes.
