10 bolt to high pinion 44 swap

[chris989]

Hello all,

I have been researching and it looks doable but i can not find a post about a completed project.

I have an 89 v2500 and I am in the process of swapping in a 4l80 from a 92. The 92 has the driver drop TC. I happen to have a 78 ford dana 44 high pinion already. I am considering swapping the axle and using the driver drop tcase. It already has the speed sensor for the 4l80.

Has anyone done this swap? Am i in for a world of headaches?

Thanks in advance

[andrewmp6]

I would rather change the t case then the front axle that is not a bolt in.

[NorCalAnthony]

Originally Posted by andrewmp6

I would rather change the t case then the front axle that is not a bolt in.

+1 I'm swapping in a 5.3 with a 4l80e in to my '89 K5 and just picked up a t-case from a '90 3/4 Suburban with a TH400 for $160. The t-case is still a NP241C and it is still passenger side drop but also has the 32 spline input and VSS needed for the 4l80e. So that's another option to think about that may or may not be cheaper than paying a shop to relocate the spring perches and shock mounts on the Ford D44.

[chris989]

Originally Posted by NorCalAnthony

+1 I'm swapping in a 5.3 with a 4l80e in to my '89 K5 and just picked up a t-case from a '90 3/4 Suburban with a TH400 for $160. The t-case is still a NP241C and it is still passenger side drop but also has the 32 spline input and VSS needed for the 4l80e. So that's another option to think about that may or may not be cheaper than paying a shop to relocate the spring perches and shock mounts on the Ford D44.

Welding is the easy part. I am going to measure up the carrier location and see if it interferes with anything. I just happen to have the 44 with 411 already. I have the computer from a 91 v2500 suburban and a 92 k2500. I am trying to not have to buy a stand alone computer for another 1k.

[NorCalAnthony]

Originally Posted by chris989

Welding is the easy part. I am going to measure up the carrier location and see if it interferes with anything. I just happen to have the 44 with 411 already. I have the computer from a 91 v2500 suburban and a 92 k2500. I am trying to not have to buy a stand alone computer for another 1k.

If you have the welder, skill, and space to do everything I'd go for it especially since you already have the parts. I didn't have a welder or the extra space for fabrication and have been trying to limit myself to using the bolt on parts... You might check the CK5 and Pirate4x4 forums to see if anyone has done this specific swap since those forums are a little more 4x4 specific and those guys get real creative with their rigs. I would just be sure to get the axle modified and verify it's fitment as best you can before you start the trans/t-case swap to minimize the down time in case you miss anything.

Are you going to keep running stock gauges? If so, you'll need to pick up a gauge cluster from a 90-91 R/V series truck with the electric speedo or pick up an adapter since the newer trans and PCM are all electric.

[chris989]

I will pick up the adapter if needed. I hate to take the dash apart again.

I will keep investigating before i tear it apart.

Chris

[andrewmp6]

On that 78 axle if its from a coil spring truck the wedges are cast in on one side and a nightmare to get off.And if it from a coil spring truck/bronco you could sell it easy,People use them for a solid axle swap on the 80-96 f150/bronco.I believe you can add a vss to almost any t case out their that don't have it.

[chris989]

it is from a 78 supercab f250. Tonight i went and remeasured and the carrier/spring perch is 3/4" different from the inner C. I will make a few more measurements but i think this blows the idea. The perch is part of the carrier housing and unless i want to start making some big changes there it will not work.

I guess i will hunt for a new speed sensor converter for my cable speedo and stick with the pass drop axle.

[andrewmp6]

You can use http://www.abbott-tach.com/cablex.htm but its 340 bucks.I'm cheap i rather swap gauge clusters to something later.

[NorCalAnthony]

Bummer that you couldn't get the Ford D44 to work.

Be sure to do some researching on the speedo adapter. Most of them are in-line adapters that screw in to the mechanical speedo cable that will allow you to keep your stock t-case and speedo while giving a VSS signal for the PCM. The problem there is everything I've seen says they only work when converting to a 4l60e since apparently the 4l80e's require a different type of signal.

One easy way of doing it (if you're lucky) would be to pull the plug on your 4l80e where the second VSS would be on a 2wd trans and check to see if you have a tone ring in there. The 2wd and 4wd versions use the same case with the 2wd having both VSS's in the case and the 4wd having one VSS in the case, a plug in the case, and then the second VSS in the t-case tail shaft. If you do have the tone ring, just buy a second VSS, plug it in, and hook your stock t-case back up to it. I've seen a few guys do it that way using the LS computer or separate trans controller. You may need the PCM from a 2wd truck for that to work though I'm not sure. If you go that route though you should be able to use your existing t-case and speedo.

If your trans doesn't have the tone ring for the second VSS, your best bet might be to get a 241 t-case from a 90-91 Burb 3/4 ton with the VSS, just be sure it had the TH400 so the spline count will match your 4l80e. If your V2500 already has a TH400 you may be able to just swap out the t-case tail shaft to save some money... Or if you have the extra coin you could get a VSS equipped adapte. Pretty much all of these other options would require you taking apart the dash and swapping in an electronic speedo though...