The Front Axle

Front Axle

Last Updated: 1/23/05

When I bought my truck it had the original Spicer 25 front axle. Due to my horsepower induced frenzy, I ended up swapping this front end out in favor of a Dana 44 from a '79 Wagoneer. The Wagoneer front end has open knuckles and large disc brakes. This makes for a relatively sharp turning radius and great stopping power.

The Wagoneer front end swap is not an easy bolt in swap. The front end is slightly wider than the Spicer 25. In order to compensate for the extra width I had to cut off the spring hangers and move them laterally about 0.5" on each side. Once the spring hangers were off, I decided to perform a shackle reversal. There was a recent discussion on the WillysTech list about the pros and cons of shackle reversals. The entire discussion can be summed up by stating that some people like shackle reversals and some people don't. My shackle reversal is working great so far.

If you clicked on the previous link you probably noticed that I also went spring over. At the time I thought the SOA conversion would be a good idea. I wanted some lift and this seemed like the best way to do it. Well, I got the lift and then some. My truck now sits far too high. The truck won't fit in my garage unless I take the front wheels off and drive it in on rims. As a result, I don't get to drive the truck as much as I would like.

There are two very important things to consider when performing the Wagoneer axle swap. The first is wheel lug bolt pattern and the second is the differential location. The wheel lug bolt pattern on the late '70s Wagoneers is 6 lug. This lug pattern won't work if you plan to keep the stock wheels. The stock Willys bolt pattern for 4wd models is 5 lug on 5.5". Fortunately, converting the 6 lug Wagoneer Dana 44 to 5 on 5.5" is quite easy.

Swap out the spindles with half-ton Chevy Dana 44 spindles. These spindles are often found in the mid '70s Chevy trucks.
Swap out the rotors (with hubs, i.e. the part with the lug studs) and wheel bearings with 1980 Ford F-150 Dana 44 parts.

The remaining Wagoneer parts (i.e. backing plates and calipers) will bolt right up to the Ford & Chevy parts. Be sure that you get the correct spindles for the swap. As shown in the picture below, the spindles needed are "small" spindles on the left.

As for the differential location; be sure to purchase a Dana 44 that has the differential on the correct side for your transfer case. If you're going to use a Spicer 18, then you need the differential on the passenger side.

I suppose I should also warn you that the Wagoneer Dana 44 is NOT setup for SOA (Spring Over Axle). If you want SOA, prepare yourself for some serious grinding and welding. After performing this modification myself, I do not recommend this conversion. In fact, I am in the planning/parts gathering stages for converting my truck back to SUA (Spring Under Axle). I recently purchased an NV4500 and NP241c that will replace my current setup, SM465/NP205. The NP241c has as a driver side front output which requires that I swap out my passenger side Dana 44 with a driver side Dana 44. Fortunately, I found a driver side version of the Dana 44 in a 1985 Wagoneer. Construction on this next project is estimated to begin in Feb. 2005.