Dana 44 SAS

[adharding]

Hey guys. Started buying stuff for my solid axle swap today. I'm gonna go with a dana 44 on leafs for the front, out of a 1994 ram 1500. Picked it up today for $50 with the steering linkages, and semi-complete brakes. For the rear, what would you guys say would be the max lift I could get out of the stock setup? I'm running the 8.0" now on a 3" suspension lift, and was thinking of dropping in the 9.5" out of the SS, AND just lifting it maybe 6" in total. I'm doing the SAS with the #1 goal of weight capacity, I'm swapping a 6.5 duramax in, and would like the extra strength up front. I'm not planning on doing any rock crawling, just mostly overlanding. Here's a pic of the new axle.

[bartonmd]

Swapping in a Duramax, you'll want a Dana-60, at the very least. Hopefully a D60 with 35-spline outers. The D60 (or AAM equivalent) is what all of the diesel trucks have run since the late 80's, even stock.

Mike

[adharding]

I think the 44 will do for now. I'm installing my 6.5 in its NA form, and it only weighs 200 lbs more than the 4.2. But then again I could just keep it gas. I still haven't 100% decided on parting out my dually for this project yet.

[Jrgunn5150]

The only hold up with lifting the rear is the tires get into the doors, you'll need longer control arms.

[Rickalicka18]

I am no expert by any means for this type of stuff, but looking at the specs of the dana 44 and the dana 60, I have to agree with Mike on using the dana 60. Weight wise, you'll probably be okay using the dana 44, but what would worry me is the amount of torque being put through the axle (approximately 440 ft-lbs at 1,800rpm) would be too much torque for that axle to handle. I would just go with a dana 60, because it will handle everything with ease.

[adharding]

The only hold up with lifting the rear is the tires get into the doors, you'll need longer control arms.

Right on. I think I can fab some up.

I am no expert by any means for this type of stuff, but looking at the specs of the dana 44 and the dana 60, I have to agree with Mike on using the dana 60. Weight wise, you'll probably be okay using the dana 44, but what would worry me is the amount of torque being put through the axle (approximately 440 ft-lbs at 1,800rpm) would be too much torque for that axle to handle. I would just go with a dana 60, because it will handle everything with ease.

I'm gonna try and beef it up when the time comes. It's gonna be a few months til I get to the diesel swap. I was gonna toss some chromoly shafts in it while I have it out still as I do all the u joints and the brakes. My cheapest local option for a dana 60 is around 800. I plan on running it with 35"s at most.

[Rickalicka18]

I mean, you have the dana 44 already so you might as well use it. If it doesn't last then you can always switch to a dana 60.

[HARDTRAILZ]

Dana 44 is better than most of us run anyway, so go for it. You can always swap it out later.

[Jrgunn5150]

Dana 44 is better than most of us run anyway, so go for it. You can always swap it out later.

I agree, go for it and if need be, it'll be easy to swap later.

[adharding]

Now out of sheer curiosity, what are you guy's thoughts on a leaf under configuration? Like I've said before, I'm not doing any rock crawling, and don't need the extra ground clearance.

[HARDTRAILZ]

I would not run it and i doubt you could do it with the height you need for oil pan clearance anyway.

You realize the 35s you want to run will look small with the basic amount of lift needed to clear the SA right?

[adharding]

I would not run it and i doubt you could do it with the height you need for oil pan clearance anyway.

You realize the 35s you want to run will look small with the basic amount of lift needed to clear the SA right?

Yeah. It's part of the reason why I've been hesitant on pulling the trigger on the SA. I was planning a custom IFS with the 3500 9.25", but $$$$. I guess I'll just have to suck it up and put big boy tires. Lol

[Jrgunn5150]

I would not run it and i doubt you could do it with the height you need for oil pan clearance anyway.

You realize the 35s you want to run will look small with the basic amount of lift needed to clear the SA right?

He's doing an engine swap also though, he can put the oil pan anywhere he likes.

There should be rear sump pans for that engine that will make it much easier to clear.

I still wouldn't bother with spring under on the front though.

[Rickalicka18]

I would not run it and i doubt you could do it with the height you need for oil pan clearance anyway.

You realize the 35s you want to run will look small with the basic amount of lift needed to clear the SA right?

Yeah. It's part of the reason why I've been hesitant on pulling the trigger on the SA. I was planning a custom IFS with the 3500 9.25", but $$$$. I guess I'll just have to suck it up and put big boy tires. Lol

Bigger is better.

[bartonmd]

I think the 44 will do for now. I'm installing my 6.5 in its NA form, and it only weighs 200 lbs more than the 4.2. But then again I could just keep it gas. I still haven't 100% decided on parting out my dually for this project yet.

Oh, the NA 6.5 pig... You said Duramax, so I assumed you had typo'd the 6.6 as 6.5, because the 6.2/6.5/6.5t were not called "Duramax." The 6.2/6.5 were made by Detroit Diesel, and the Duramax 6.6 is made by Isuzu.

IMO, sell the D44 for $250 and buy the $800 D60. You'll have more than $550 in chromo-ing the D44 to try and get it to live. Also remember that if you are doing a doubler, torque does multiply by speed reduction, so the torque to the axle will double from a stock setup. Keeping the 4.2L and the stock T-case ratio (i.e. not adding a doubler or going to an Atlas 4:1 or something), sure the D44 is fine (though the 3/4-ton D44 has thicker tubes than the 1/2-ton D44).

Mike

[adharding]

Some progress today. pulled the axle into the wash bay, cleaned it up, and took measurements to order parts. Spring perches are on their way, along with a larger carrier and install kit. the current gearing is a 3.54, on the smaller carrier. threw some 35x12.5"x17 tires on over the weekend. very tight fit, and no real articulation until they get remounted onto 6x5.5" silverado 17" wheels, or procomps. Haven't decided yet. here's a pic after 35" tires. i'm currently running a 3" suspension lift and 3" body lift.