Revolution Gear & Axle 69-79 Ford F-150 Dana 44 Chromoly Discovery Series Front Axle Kit

If the front Dana 44 under your 1969-1979 Ford F-150 has snapped an inner shaft, twisted a stub, or you are about to bolt on bigger tires and lockers, this is the kit that replaces every rotating shaft between the carrier and the hubs. Revolution Gear and Axle part DC-D44-F150 is a Discovery Series 4340 chromoly front axle kit built for the Ford half-ton straight-axle Dana 44, and Revolution also lists it for the 1978-79 full-size Bronco that shares that front axle.

What the front axle shafts do in a Ford Dana 44

On the solid-axle Ford half-ton, the Dana 44 front carrier sends power out through a long inner shaft on one side and a short inner shaft on the other. Each inner shaft ends in a U-joint yoke that sits inside the steering knuckle; the outer stub shaft on the other side of the joint passes through the spindle and drives the locking hub. When you turn the wheel, the U-joint lets the stub swing with the knuckle while still carrying torque. That joint and the splines on both ends of each shaft are where an old front axle gives up first, especially at full lock with traction under the tire.

This kit includes two 4340 chromoly inner axles, two 4340 chromoly outer stub axles, two Dana Spicer 5-760X U-joints, and eight full-circle snap rings. Axle seals are not included, so plan on ordering inner seals and a seal driver if you are opening the housing.

Symptoms that point to the front shafts

• Loud bang in four-wheel drive followed by no front pull, or the front driveshaft turning with no wheel movement on one side.
• Clicking or popping when turning in 4WD, the classic sign of a dry or failing U-joint in the knuckle.
• Steering wheel shake or binding while turning in 4WD that goes away in two-wheel drive.
• Gear oil weeping from the knuckle area, which usually means the inner seal is leaking and the U-joint has been washed or starved.
• Visible twist marks or rounded splines on a stub shaft when the hub is pulled.

How to confirm before you buy

Jack up the front, lock the hubs, and turn each wheel by hand with the transfer case in neutral. A wheel that spins freely while the opposite wheel and front driveshaft stay still points to a broken inner shaft, stub, or U-joint on that side. Pull the hub and spindle to look at the joint directly. Seized or notchy joints, rust-colored grease, and cracked cross ears are worth replacing on their own; twisted or chewed splines mean the shafts themselves are done. Our Dana 44 axle problems and rebuild cost guide walks through the carrier side, and the chromoly vs stock axle shaft guide explains when the upgrade is worth the money.

Fitment

The listing covers the Ford F-150 from 1969 to 1979 with the Dana 44 front axle, and Revolution's own catalog adds the 1978-79 Bronco. The earlier 1966-77 Bronco uses a different kit, so do not cross-shop by axle name alone. The F-150 badge itself arrived in 1975, so if you have an earlier half-ton 4x4 or any truck that has had an axle swap, send us the year and VIN before ordering and we will confirm. Count the splines on your old shafts and compare the stub length against the old parts before installing. You can browse other front-axle hard parts in our hard parts category.

Install notes

• Remove the locking hubs, wheel bearings, and spindle on each side, then pull the inner and outer shaft assemblies out as one piece.
• Install new inner axle seals in the housing tubes before the shafts go in. A Dana 30/44/60 inner axle seal installer keeps the seal square so it does not leak on day one.
• The 5-760X joints are pressed into the yokes and held with the supplied full-circle snap rings. A ball joint and U-joint press kit makes this a bench job instead of a hammer job.
• Slide the shafts in slowly so the inner splines find the side gears without cutting the new seals.
• Repack the wheel bearings, set preload per the factory procedure, and inspect the hubs; worn hub internals are a common source of front-end slop on these trucks. See the Yukon Hardcore Dana 44 locking hub set and match the spline count before ordering.
• Top off the front differential with 75W-90 gear oil after the install.

What comes in the Revolution DC-D44-F150 kit?

Two 4340 chromoly inner axles, two 4340 chromoly outer stub axles, two Dana Spicer 5-760X U-joints, and eight full-circle snap rings. Axle seals are not included.

Will this fit my 1978 or 1979 Ford Bronco?

Revolution lists this kit for the 1978-79 Bronco with the Dana 44 front as well as the 1969-79 F-150. The 1966-77 early Bronco takes a different kit.

Do I need new axle seals with this kit?

Yes. Seals are not in the box, and any time the shafts come out the inner tube seals should be replaced so gear oil does not wash out the new U-joints.

What gear oil goes in the front Dana 44 afterward?

75W-90 gear oil is the common fill. If you have installed a clutch-type limited slip, add friction modifier as that unit's maker specifies.

How do I know my truck has a Dana 44 front and not a swapped axle?

Look for the Dana tag or the cast 44 on the housing and count the cover bolts and shaft splines. If the truck has been modified, send the year and VIN with photos and we will help confirm.