Good response Jon. Glad you found Mr. N`s information. Very informative and current.
From experience in re-tubing. 3 HP Dana 60`s in the last couple years. It is a nasty pain in the butt job that requires tools most folks do not have.
Hold out for an F250 HP44 that has ll the tube you might want. Narrow it to whatever width you are looking for.
You know another consideration.......Several companies (including Dana) sell just the bare housing at a pretty reasonable cost. That way you could build your axle with whatever tube length/thickness you want. Not have to screw around trying to retube or narrow a full width axle.
DTS in Michigan, Solid, Rockcrusher, Tera are a few that come to mind for center sections.
Inner C`s and knuckles can be had for cheap and you could choose between Chevy of Ford outters.
As much as I like the Ford 9 inch you are faced with two issues. Both can be overcome but why ?
1. The pinion height on the 9 inch is very low. Meaning your DS angle will be severe.
2. The typical 9 inch housing is not very strong. Bent tubes are a real possibility without a top and rear truss. Now the trusses get in the way of the gas tank. Much better to use an aftermarket housing that is designed for off road usage.
For kicks here is a chart on pinion height and DS lengths for comparison.
True Hi9 - Driveshaft Comparison pinion height hi high ford inch 9 nine
I like the 8.8 with Moser 7750DB ends. Allows for bigger/better bearings. Gets rid on the C-clip and still allows all your disc brake/parking brake stuff for a nice clean install. Consider an LPW girdle to stiffen the whole center section and reduce gear deflection.
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