Braptorizing 2 door Bronco... First Edition Warthog...

[Felix808]

I haven't broke the pinion, only the teeth on the ring gear... on both the front and the rear.

clamshell housings are notorious for deflection or case stretch under loads. the OEM rear m220 can withstand FAR more abuse than the m190 or m210.

That's what usually happens and as you mention the flex or deflection allowing variances of pinon gear engagement putting more load on less surface area of the ring gear, causing teeth to part ways with the ring gear .

What is your rear diff clearance to ground?

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[Valhalla]

Have you considered S.A.S. (solid axle swap)? I don't know that at this weight / power ratio it isn't more reliable. Not saying I haven't toyed with the same idea on my 1996. I'd thought of trying to fab a TTB with a super 60. Shelved the idea as I already have more hobbies than time and money .

 

[BigMeatsBronco]

Have you considered S.A.S. (solid axle swap)? I don't know that at this weight / power ratio it isn't more reliable. Not saying I haven't toyed with the same idea on my 1996. I'd thought of trying to fab a TTB with a super 60. Shelved the idea as I already have more hobbies than time and money .

Naw, no way...Solid axles are for Neanderthals and jeeps.

 

[Valhalla]

Naw, no way...Solid axles are for Neanderthals and jeeps.

Lol...gotcha

 

[BigMeatsBronco]

What is your rear diff clearance to ground?

13.5" with 27 lbs air pressure

 

[Felix808]

13.5" with 27 lbs air pressure

Thanks. You got me by 1 3 /4" with 5" more tire (2.5" clearance by tire) . So it looks like it's about 3/4" between the SF D60 & the current M220. Stronger tubes, carrier, 35 vs 32 spline & overall strength no doubt but would be curious as to how much stronger given the extra weight & forces involved with the 42's Just a shame a full float D60 would be so cost prohibitive with having to change wheels on top of the $6500+ not to mention the front axle upgrade & such.

Thanks again

 

[Fordified1]

Thanks. You got me by 1 3 /4" with 5" more tire (2.5" clearance by tire) . So it looks like it's about 3/4" between the SF D60 & the current M220. Stronger tubes, carrier, 35 vs 32 spline & overall strength no doubt but would be curious as to how much stronger given the extra weight & forces involved with the 42's Just a shame a full float D60 would be so cost prohibitive with having to change wheels on top of the $6500+ not to mention the front axle upgrade & such.

Thanks again

I wish someone made a bolt-in Ford 9” housing for our Broncos. Curry has no interest in doing one even though they built their business on the 9” Ford.

 

[Felix808]

I wish someone made a bolt-in Ford 9” housing for our Broncos. Curry has no interest in doing one even though they built their business on the 9” Ford.

I use to think that. Had Currie build me a 9" for my XJ way back when. Had I known at the time, I should have just swapped an exploders 8.8.
When going big like @BigMeatsBronco has done, I think the D60 is the right way to go. It's just sad we don't have a viable full float D60 option instead we got what they gave us

 

[Fordified1]

I use to think that. Had Currie build me a 9" for my XJ way back when. Had I known at the time, I should have just swapped an exploders 8.8.
When going big like @BigMeatsBronco has done, I think the D60 is the right way to go. It's just sad we don't have a viable full float D60 option instead we got what they gave us

I actually have a couple V8 Explorer 8.8’s. One in the truck one on the ground. Probably going in an early Ford truck project. A 9” is stronger though. You don’t have to weld the tubes for extreme use, and the gears are easier to set up on the bench. Sure, the full float 60 is a beast. I don’t relish the idea of welding the steel tubes to the cast center housing though… and I weld for a living.

 

[Felix808]

On an XJ the 8.8 is / would've been a much more economical solution than a a custom 31 spline 9" from Currie for me. Though the 9" was a much better axle. The price of education I suppose .

The 9" is more of an intermediate axle, even with 35 spline units. While a good bit stronger that the M220, the 9" tubes just can't match the D60's strength in full float form. I don't know too much about the SF unit available, but the 9" would be a heck of a lot lighter. The 9" has a much lower pinon but albeit stronger due to the extra pinon support. I believe if we had stronger tubes, the M220 would still be the ticket for most, having 32 spline axles. But as you mention setting gears up on the bench is so much nicer .

 

[87-Z28]

Indeed.

Stronger tubes is a big deal. Here is a plot I made for tube strength normalized to the OEM M220. Some hypothetical tube diameters as a function of wall thicknesses. Increasing tube diameter is a bigger benefit than wall thickness but both help. The D60 is almost 3 times as strong as the M220.

if the M220 was 3.25” diameter with same wall thickness to reduce weight it would be nice. 1.75 current strength.

 

[BigMeatsBronco]

Thanks. You got me by 1 3 /4" with 5" more tire (2.5" clearance by tire) . So it looks like it's about 3/4" between the SF D60 & the current M220. Stronger tubes, carrier, 35 vs 32 spline & overall strength no doubt but would be curious as to how much stronger given the extra weight & forces involved with the 42's Just a shame a full float D60 would be so cost prohibitive with having to change wheels on top of the $6500+ not to mention the front axle upgrade & such.

Thanks again

you don't necessarily have to change wheels. you could do Full float with. 99 -04 F450 unit Bearing setup redrilled. to the Bronco 6 lug, plenty of companies offering different custom versions, spidertrax makes several... also they sell a prefab "cup" that you weld on the end of the axle tubes, that has the same bolt pattern as the unit bearing...no need for the old style FF with fixed spindles... also these are available in several spline counts as well. 35 and 40..ect. I figure if I break one of the spicer ultimate 60 Chromoly axles I'll upgrade to the unit bearings Style at that point and go to a 40 spline shaft and Locker. Although for semi float, everybody says tire size 40 inches is the limit even with the bigger bearing boss, bigger end of the axle shaft and double roller bearings ... 40 inches is still the limit and I'm running 41x14.50r17 IROKS.


https://www.spidertrax.com/Ultimate-Unit-Bearing-6-on-5-1-2-x-5-8-Studs-x-RH

 

[Felix808]

you don't necessarily have to change wheels. you could do Full float with. 99 -04 F450 unit Bearing setup redrilled. to the Bronco 6 lug, plenty of companies offering different custom versions, spidertrax makes several... also they sell a prefab "cup" that you weld on the end of the axle tubes, that has the same bolt pattern as the unit bearing...no need for the old style FF with fixed spindles... also these are available in several spline counts as well. 35 and 40..ect. I figure if I break one of the spicer ultimate 60 Chromoly axles I'll upgrade to the unit bearings Style at that point and go to a 40 spline shaft and Locker. Although for semi float, everybody says tire size 40 inches is the limit even with the bigger bearing boss, bigger end of the axle shaft and double roller bearings ... 40 inches is still the limit and I'm running 41x14.50r17 IROKS.


https://www.spidertrax.com/Ultimate-Unit-Bearing-6-on-5-1-2-x-5-8-Studs-x-RH

With the non-fixed full float spindle ends, I picture it would be a bit of trouble to swap shafts? With the fixed style it's fairly quick & simple provided you can get all the bits out of the carrier.

Interesting stuff. Thanks for sharing

 

[BigMeatsBronco]

With the non-fixed full float spindle ends, I picture it would be a bit of trouble to swap shafts? With the fixed style it's fairly quick & simple provided you can get all the bits out of the carrier.

Interesting stuff. Thanks for sharing

correct, if you're only changing the axle shaft itself then yes the full floater unit bearings are going to be more difficult as the axle has no flange it just has splines on both ends. On the other hand only need to remove the brakes and the four bolts holding unit bearing in and there's your axle ready to pull.

 

[Valhalla]

I wish someone made a bolt-in Ford 9” housing for our Broncos. Curry has no interest in doing one even though they built their business on the 9” Ford.

Currie is making one according to a supplier I was talking to.

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