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Ranger Alignment Cam

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To mate the Dana 44 outers successfully with the Dana 35 Twin Traction Beams, we decided to modify a pair of Ranger alignment cams. We started by enlarging the alignment cams' bore enough to slip a short length of 7/8" x .065 chromoly tubing inside. We then TIG welded the tubes into place in the alignment cams. The Ranger alignment cams' bores are non-tapered, while the shank of the Dana 44 upper ball joint has a taper; we'll ream the F-150 ball-joint taper into the welded sleeve. In this instance, we chose to use 4130 chromoly because it is seamless, not because of its strength characteristics. In the end, we decided that the 4130 was the wrong material. Its hardness dulled our cutting tools, and cost a lot of extra time. DOM tubing would have been the way to go. The Drawn Over Mandrel manufacturing process means that the seam is flattened. There's nothing like 20/20 hindsight.

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