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Thread: Fabricated 4WD Diffs based on the Ford 9"

  1. #1
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    Fabricated 4WD Diffs based on the Ford 9"

    Could be some good things happening in the shed soon however I need to do some more research and I was hoping to get some opinions / advice.

    So a couple of questions;

    • Advice on a strong setup based on a Ford 9" diff / axle, needs to retain ABS.
    • What 4WD vehicles came standard with a Ford 9" diff?
    Thoughts on the setup so far;
    • Aftermarket 9" case with thick wall axle tubes cut to suit.
    • True Hi9 3rd Member with ARB locker and 4.11
    • 35 spline axles
    • Not sure on best options for steering knuckles etc. (needs to have ABS)
    Any comments / advice would be appreciated.

  2. #2
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    Why a 9"?
    Bronco and f truck had 9" diffs, pretty sure front was a low pinion though.
    Ashcrofts do the hi9.

    Personally the front diff that john (bush65) is probably an easier/better option.

  3. #3
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    Why not front and rear Dana 60's, nearly all bolt straight in.

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    The idea of the Ford 9 was to utilise the High Pinion True Hi9 3rd members however I am open to all suggestions at this stage.

    I will check out the Dana 60 gear, what vehicles came with Dana 60 as standard?

  5. #5
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    The reason I said dana60, is you can modify a Salisbury rather easy to take dana60 gear, you can also buy a front Salisbury for a land rover that bolts straight in. Just need to get some 35spline axles (Keith from roving tracks can organise this).
    You do end up with a bit of a plow though, but nothing big rubber or portals can't fix

  6. #6
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    Thanks Vern, Yeah, I know about the options with the Sals and Dana 60 gear from other builds / threads I have read on here and Pirate.

    I dont think Keith is doing anything anymore, however I could be wrong. There is heaps of Dana 60 aftermarket gear available from the US though.

    The benefits I saw with the Ford 9 was the smaller housing and for their strength they are quiet light weight too, especially with aftermarket housings etc.

    Big rubber and portals would be awesome but I do not think possible, not at this stage anyway.

  7. #7
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    Quote Originally Posted by CJT View Post
    Thanks Vern, Yeah, I know about the options with the Sals and Dana 60 gear from other builds / threads I have read on here and Pirate.

    I dont think Keith is doing anything anymore, however I could be wrong. There is heaps of Dana 60 aftermarket gear available from the US though.

    The benefits I saw with the Ford 9 was the smaller housing and for their strength they are quiet light weight too, especially with aftermarket housings etc.

    Big rubber and portals would be awesome but I do not think possible, not at this stage anyway.
    What will it cost to fabricate new housings to use 9" centres? Have a look at The New Halibrand. Not super expensive and they will make them to the width you require. Also google Speedway Motors.
    URSUSMAJOR

  8. #8
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    Quote Originally Posted by Brian Hjelm View Post
    What will it cost to fabricate new housings to use 9" centres? Have a look at The New Halibrand. Not super expensive and they will make them to the width you require. Also google Speedway Motors.
    Around $1,000 for the rear and $2,000 for the front housing with knuckles etc.

  9. #9
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    my 0.2 cents:

    There is just as much support for the for the 9 as there is the D60. Maybe even more when you consider housing choices. ATM there are only a couple of AM housings for D60 and only one that does a full fabricated housing and turns the D60 into a drop out third like the Rover/Ford diff.

    Front end: There is no point running super strong diff and axles if you are limited to some **** weak (in comparasin) CV or U joint! You will not get a bigger CV in the coil sprung swivel ball and housing without mods and these are then a one off.....

    I much prefer the idea of a drop out 3rd and fabricated housing than the big cast Dana center section etc. And If you are building this bad boy to be tough, you may want to steer clear of a Sals housing any way (pulled axle tubes)

    Is Ashcroft running the Tru Hi-9 or their own center section? I know they have their own design and cut R+P???

    If you are going a new fabbed housing, no need to source the diff from a wreck or such as you want the centre section to be of nodular iron or better. Some of the OEM truck and car applications dont have nodular iron centre sections and are known to crack/fail.

    A common combo is a ford 9 type housing and diff with D60 outers. What ever you do, make sure you go full floating design.....

    What HP will you have?
    What tyre size will you run?
    What type of driving will you do?

    Also it seems that alot of "pro" axles coming out of the states are pretty average, that is good material and cheap design. They buy a blank and machine the spline in the end. I have seen them where the main body of the axle is a slightly larger dia that the OD of the spline It also seems that alot of the "pro" R+P are not actually made in the USA and are weaker than OEM, ie Dana Spicer is better.

  10. #10
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    Quote Originally Posted by uninformed View Post
    my 0.2 cents:

    There is just as much support for the for the 9 as there is the D60. Maybe even more when you consider housing choices. ATM there are only a couple of AM housings for D60 and only one that does a full fabricated housing and turns the D60 into a drop out third like the Rover/Ford diff.

    Front end: There is no point running super strong diff and axles if you are limited to some **** weak (in comparasin) CV or U joint! You will not get a bigger CV in the coil sprung swivel ball and housing without mods and these are then a one off.....

    I much prefer the idea of a drop out 3rd and fabricated housing than the big cast Dana center section etc. And If you are building this bad boy to be tough, you may want to steer clear of a Sals housing any way (pulled axle tubes)

    Is Ashcroft running the Tru Hi-9 or their own center section? I know they have their own design and cut R+P???

    If you are going a new fabbed housing, no need to source the diff from a wreck or such as you want the centre section to be of nodular iron or better. Some of the OEM truck and car applications dont have nodular iron centre sections and are known to crack/fail.

    A common combo is a ford 9 type housing and diff with D60 outers. What ever you do, make sure you go full floating design.....

    What HP will you have?
    What tyre size will you run?
    What type of driving will you do?

    Also it seems that alot of "pro" axles coming out of the states are pretty average, that is good material and cheap design. They buy a blank and machine the spline in the end. I have seen them where the main body of the axle is a slightly larger dia that the OD of the spline It also seems that alot of the "pro" R+P are not actually made in the USA and are weaker than OEM, ie Dana Spicer is better.

    Thanks for information.

    That is actually the way I am heading, Ford 9 centre and Dana 60 outers with D60 CV's etc.

    The only reason for the question regarding standard vehicles that came with the Ford 9 and D60 is for my engineer, tyre size of equivalent factory vehicle +50mm, also to work out the maximum wheel track +50mm from the "donor" vehicle.

    I have found that the Ford 9" was in production up to the late 80's in 4wd's, mainly the Ford F100, F150 and Bronco. The Dana 60 is still used now in most of the big American pickups, Chev, Dodge and Ford up to the F450/550.

    I believe that Ashcroft developed their own 3rd however they are no longer building them as there was not enough interest.

    To answer your questions;

    HP = At first not much at all but that is likely to change in the future depending on how big transport will allow the engine capacity.

    Tyres = 33's approved for on road use, 4wd parks / comps the biggest that will fit but probably looking at 35's as I do not run extra long bump stops, my 33's only just clear the upper wheel well now after the big guard cut.

    Driving = Everything, it is now a weekend toy and will see a bit of everything from touring to comps and everything in between.

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