Looking through the list, it appears the bulk of the parts are available and when pieced together would run about $675 +/-. Bronco Graveyard might even have a kit that has most of the parts in one place.
But, that is without axle shafts. Axle shaft prices can vary wildly.
So, any idea on the specifications for the axle shafts? I assume they are 19 spline outer and 29 spline inner, but length, spline length, seal locations, seal diameter, etc.... ???
Even with all that, there would be some “machine” work needed on the ford spindle to trim the top bolt hole off and clip the bottom 2 sides so it will fit in the brake drum. That can be done free hand as none of those surfaces are super critical. Or find someone with a mill and become good friends with them.
The shafts have 30 spline outers. You can use 30 spline Dana 44 internal mount hubs and drive flanges.
The spindles are custom. I have not seen any stock spindles that will work. The Ford spindles are really long, and they use those hubs that are really long, which would cause the lock in hubs to stick out way past the wheel.
The threaded portion of the spindle, where the spindle nuts go, is shorter then regular Dana 44 stuff. The Warn kits come with one of the spindle nuts machined down to work.
IIRC, the Warn rear full float axle kit wheel hubs are the same parts they use for their HD Dana 30 internal mount hub conversions.
Shafts could be made by Moser. Wheel hubs can be sourced. The spindles are the trick.
The spindles also have a continuous lip on the back side that goes inside the axle tube. In that way, the nuts and bolts are not the only thing carrying the load, the spindle keys inside the axle tube.
I just bought a spindle that was on ebay. (The one in the photos above) Should be in my hands by Monday. I'll look it over and make a dimensional drawing that can be used for reproductions.
I need to find an f150 spindle to put my hands on. Need to see if there is enough meat in the places that need to be cut down. Not thrilled at the possibility of spending $175 for a spindle that cant be made to work. Might just keep my eyes open for a used one on Ebay.
The Yukon YA W37132 kit comes with wheel hubs, and 27 spline Warn locking hubs, to convert the front axles of our Jeeps.
The Yukon YA W61650 kit comes with wheel hubs, and 30 spline Warn locking hubs, to convert the front axles of older Jeeps... but will work on our rear axles as well, if we can find the proper stub axles!
I own the Warn full-float AMC20 kit, and I recently bought the Yukon D30 front axle kit, and I can verify that the wheels hubs are the same.
Finding or producing a modified Ford axle would be fantastic!
I have been slacking in this project. I have the warn spindle in hand, and I bought a ford spindle and have it in hand. I did some quick measurements, and it should be able to be machined down to match the warn spindle.
The only questionable area is the part that keys into the axle tube. I think there is enough meat there to duplicate the warn piece, but it will be very close if not 1/16" too shallow.
I'll try to do some measurements and photos tonight after a quick run to San Antonio this afternoon.
I plan to get with a buddy that has a lathe (several) and knee mill (several) and have the ford part machined into the warn part. If all goes well I'll document the process. I had even thought about buying my own lathe to play with, but I think it would just spread my resources (time) too thin.