{"id":1349,"date":"2026-01-14T23:27:33","date_gmt":"2026-01-15T07:27:33","guid":{"rendered":"https:\/\/www.nickpisca.com\/diesel\/?p=1349"},"modified":"2026-02-05T16:20:56","modified_gmt":"2026-02-06T00:20:56","slug":"ongoing-quadravan-conversion-project-for-the-diesel-econoline","status":"publish","type":"post","link":"https:\/\/www.nickpisca.com\/diesel\/engine\/overdrive\/ongoing-quadravan-conversion-project-for-the-diesel-econoline\/","title":{"rendered":"Ongoing Quadravan Conversion Project for the Diesel Econoline"},"content":{"rendered":"<p>I&#8217;m long overdue for some posts to this website.\u00a0 Back in 2021, I got a front Dana 44 axle from a seller in Detroit.\u00a0 It was a short roadtrip compared to <a href=\"http:\/\/www.nickpisca.com\/wvo\">our crazy roadtrips across the world<\/a>, but worth it since I got that whole setup for $800!!!\u00a0 Suspension, axle, brakes, everything.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1350\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101448.jpg\" alt=\"\" width=\"1244\" height=\"700\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101448.jpg 1244w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101448-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101448-1024x576.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101448-768x432.jpg 768w\" sizes=\"(max-width: 1244px) 100vw, 1244px\" \/><\/p>\n<p>Well, that was a long time ago.\u00a0 And I&#8217;ve been putting this project off for about four years and I&#8217;m sick of waiting for 4WD.\u00a0 After spending thanksgiving with my friend and doing some kitchen renovation with him, I got motivated to actually rebuild this beast and get it going.<\/p>\n<p>Overview:<\/p>\n<p>There are going to be a million things to do.<\/p>\n<ul>\n<li>Get a short-shaft C6 tranny that fits a 7.3 IDI.<\/li>\n<li>Get a transfer case<\/li>\n<li>Get Gearvendor adapter that goes from <a href=\"https:\/\/www.nickpisca.com\/diesel\/category\/engine\/overdrive\/\">my standard C6 tailshaft adapter<\/a> to something that mates up after the transfer case.<\/li>\n<\/ul>\n<p>I won&#8217;t be able to use the 4WD and Gearvender at the same time, because the rear axle will be at a different ratio than the front, but that&#8217;s fine.\u00a0 I hope I&#8217;m not gearsplitting in the snow in the Sierras at 50mph\u00a0 \ud83d\ude42<\/p>\n<p>Another wildcard will be to determine the gear ratio, and if it&#8217;s not a match with the rear axle, do some hard-rocking differential pinion gear swapping.<\/p>\n<p>Add to the list:<\/p>\n<ul>\n<li>Get a new pinion ring gear and pinion shaft for the 3.55<\/li>\n<\/ul>\n<p>Also, I&#8217;ll need a bunch of parts.\u00a0 This Quadravan shaft is trashed.\u00a0 TIME TO BUY:<\/p>\n<ul>\n<li>Get Seals<\/li>\n<li>Get Bearings<\/li>\n<li>Get U Joints<\/li>\n<li>Get Shocks<\/li>\n<li>Get Ball Joints<\/li>\n<li>Get lots of synthetic grease<\/li>\n<li>Get Steering Stabilizer<\/li>\n<li>Get Caliper rebuild kits<\/li>\n<li>Get Rotors, if necessary<\/li>\n<li>Get Suspension Bushings<\/li>\n<li>Get lots more.<\/li>\n<\/ul>\n<p>Let&#8217;s go over the mess of parts I have already:<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1351\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101505.jpg\" alt=\"\" width=\"1244\" height=\"700\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101505.jpg 1244w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101505-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101505-1024x576.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101505-768x432.jpg 768w\" sizes=\"(max-width: 1244px) 100vw, 1244px\" \/><\/p>\n<p>Looks like I have the Coil Receiver, Coil, some kind of double-shock setup (looks DIY), brake calipers (from 1979), brake pads, rusty rotors, FWD lockouts, old shocks, etc.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1352\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101515.jpg\" alt=\"\" width=\"1244\" height=\"700\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101515.jpg 1244w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101515-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101515-1024x576.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101515-768x432.jpg 768w\" sizes=\"(max-width: 1244px) 100vw, 1244px\" \/><\/p>\n<p>Also, they gave me a set of rear leaf springs.\u00a0 Turns out the Quadravan kit came with leafs to get the vans to ride more level after the front axle lifted the front end up a bit.<\/p>\n<p>There are some suspension components all attached together.\u00a0 Radius Arms with bushings, center link, tie rods, and some other parts.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1353\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101524.jpg\" alt=\"\" width=\"1244\" height=\"700\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101524.jpg 1244w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101524-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101524-1024x576.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101524-768x432.jpg 768w\" sizes=\"(max-width: 1244px) 100vw, 1244px\" \/><\/p>\n<p>The rotor shields are totally trashed.\u00a0 They&#8217;ll either need to be replaced or significantly reshaped on the vice and anvil.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1354\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101531.jpg\" alt=\"\" width=\"1244\" height=\"700\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101531.jpg 1244w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101531-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101531-1024x576.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101531-768x432.jpg 768w\" sizes=\"(max-width: 1244px) 100vw, 1244px\" \/><\/p>\n<p>Well, back in 2021, in my dad&#8217;s shed, who coincidentally let me store that axle for a couple years and leave a greasy mess on his new shed floor in Wisconsin, I took the time to disassemble the kit into manageable pieces for the drive to Los Angeles.\u00a0 I ended up driving all those parts cross-country back in 2023, and they just sat in my garage until now.<\/p>\n<p><strong>Dana 44 FWD<\/strong><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1355\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101607.jpg\" alt=\"\" width=\"1244\" height=\"700\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101607.jpg 1244w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101607-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101607-1024x576.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20210719_101607-768x432.jpg 768w\" sizes=\"(max-width: 1244px) 100vw, 1244px\" \/><\/p>\n<p>Yes.\u00a0 I got a Dana 44.\u00a0 Before you blow up the comments with &#8220;shudda gotta Dana 60,&#8221; hold your wad.\u00a0 I&#8217;m not taking my van to the top of Mt Whitney.\u00a0 It&#8217;s mostly a highway roadtripping van, and I like the option of turning on 4WD if I need it.\u00a0 It&#8217;ll be not common, but I like it.\u00a0 Just like I like adding a turbo just cuz.\u00a0 Also like adding an GVOD just cuz.\u00a0 This is my &#8220;just cuz&#8221; project cuz I&#8217;m getting old and I just want it.<\/p>\n<p>The axle is dirty, grimy, ugly, and old.\u00a0 But overall, it&#8217;s intact.\u00a0 With a little elbow grease, new parts, paint, and TLC, it could transform into something useful.<\/p>\n<p>In 2023, I found a NP208F transfer case for sale in Los Angeles of all places.\u00a0 $100.\u00a0 The guy sold it from some place like Alhambra, so I just drove over and picked it up.\u00a0 He had a bunch of rice grinders so either his truck project was abandoned or he stole it.\u00a0 Who knows at this point.<\/p>\n<p><strong>Chapter Irony:<\/strong><\/p>\n<p>I set up an automatic search on eBay for &#8220;NP208F Gearvender&#8221; in the hopes that some day some one some where they&#8217;ll sell one.\u00a0 BUT Gearvender has a standing policy to stop all reselling of adapters.\u00a0 Just try it.\u00a0 They don&#8217;t like it.\u00a0 They want you to buy directly from them.\u00a0 I&#8217;m not upset about that, but just in case I stumble on a lucky sale, I&#8217;ll get it.<\/p>\n<p>I called up Gearvenders and asked if they ever sold any of the adapter for the t-case NP208F, and surprisingly they had several in stock.\u00a0 Not that expensive either.\u00a0 $550 IIRC.\u00a0 They included the gaskets and rebuild kit as well.\u00a0 I have <a href=\"https:\/\/www.nickpisca.com\/diesel\/engine\/gearvender-deep-sump-installation-tutorial-maximum-overdrive\/\">the J-Type with the Maximum Overdrive Deep Sump<\/a>, so it&#8217;ll mate well with the new adapter.<\/p>\n<p>A few days later, I found a Gearvendor adapter for the NP208F on eBay.\u00a0 LOL.\u00a0 Typical.\u00a0 I bought it anyway.\u00a0 Now I have two, just in case.\u00a0 Why have one, when you can have two at the price of two?<\/p>\n<p><strong>Transmission Issues:<\/strong><\/p>\n<p>A friend from the Milwaukee area was selling various diesel IDI C6 4WD parts.\u00a0 He is Andrew, and he had me full C6 short-shaft, just needed to pick it up for $200.\u00a0 The only catch was I was in LA, and it was 2023.\u00a0 Thankfully he held on to it for a few months until I could meet up with him around Christmas.\u00a0 Everything was good aside from the whole trans being in a million pieces.\u00a0 Not quite sure how to deal with that mess, but it&#8217;ll work.\u00a0 Maybe I can combine all the parts from my two good long-shaft C6&#8217;s and make one decent short-shaft C6.<\/p>\n<p>Driveshaft?\u00a0 Not a problem.\u00a0 I&#8217;ll worry about that last.<\/p>\n<p><strong>Rear Suspension:<\/strong><\/p>\n<p>I need to make a retroactive post about that.\u00a0 In 2023, I got really annoyed with my slumpy saggy old leafs.\u00a0 Check this:<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1361\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20220524_121143sfw.jpg\" alt=\"\" width=\"800\" height=\"450\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20220524_121143sfw.jpg 800w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20220524_121143sfw-300x169.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20220524_121143sfw-768x432.jpg 768w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/p>\n<p>I installed the quadravan rear leafs early.\u00a0 I took a bunch of photos and videos, and then I just forgot to post it.\u00a0 Ultimately, it&#8217;s not that complicated.\u00a0 Remove the u-bolt nuts, spring bolts, and install springs.<\/p>\n<p>It sits up a lot higher, and it&#8217;s a lot springy-er.\u00a0 It&#8217;s great when I&#8217;m hauling a bunch of people or house project supplies, but when the van is empty, it&#8217;s like a scared rabbit.\u00a0 Jumpy as hell.<\/p>\n<p><strong>Building the Jig.<\/strong><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1358\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251210_103151.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251210_103151.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251210_103151-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251210_103151-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251210_103151-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/>Glenn and I drove the axle back to LA in 2023.\u00a0 It&#8217;s a beast.\u00a0 Likely a few hundred pounds and it takes more than two guys to carry around.\u00a0 I set up the shop crane to lift it out of the van and drop it on the shop floor.<\/p>\n<div id=\"attachment_1448\" style=\"width: 310px\" class=\"wp-caption alignright\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1448\" class=\"wp-image-1448 size-medium\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20260116_axle-300x256.jpg\" alt=\"The Jig. Axle Support so that I'm not sliding this thing around on the concrete all the time. I'm old.\" width=\"300\" height=\"256\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20260116_axle-300x256.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20260116_axle.jpg 500w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><p id=\"caption-attachment-1448\" class=\"wp-caption-text\">The Jig. Axle Support so that I&#8217;m not sliding this thing around on the concrete all the time. I&#8217;m old.<\/p><\/div>\n<p>Right away, I realized this wasn&#8217;t going to work.\u00a0 It&#8217;s about 7 ft long and too heavy to slide around.\u00a0 \u00a0I need a thing that will put this axle about 2ft off the ground and be easy to wheel around. Glenn and I used all the scrap wood in the shed to make a crude jig.<\/p>\n<p>Luckily, I had a bunch of sturdy casters from my buddy Ryan that just gave them to me a couple years back.\u00a0 They even had some nice steel receivers built in to the caster.\u00a0 You can see the casters in the back of the image above (they are red).<\/p>\n<p>The jig worked well.\u00a0 I left the diagonals to extend up passed the box, so that there was no torsional movement and they kept the axle from sliding off the platform.<\/p>\n<p><strong>Getting STARTED.<\/strong><\/p>\n<p>Here it is.\u00a0 Yikes.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1359\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141713.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141713.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141713-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141713-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141713-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/> <img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1360\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141717.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141717.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141717-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141717-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141717-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/><\/p>\n<p>I removed the coil assembly, central stabilizers, and radius arms.\u00a0 Not in the photo.\u00a0 They are in the backyard, collecting dust and rust.<\/p>\n<p>Are these tie rods salvageable?<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1362\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141721.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141721.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141721-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141721-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141721-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/><\/p>\n<p>Rotors look a little rough, but useable.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1363\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141739.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141739.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141739-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141739-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141739-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/><\/p>\n<p>Calipers look grimey, but that could&#8217;ve been all the penetrating oil that I used to disassemble the kit.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1364\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141749.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141749.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141749-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141749-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141749-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/><\/p>\n<p>U-joints on both sides look rusty and like they&#8217;ve been in a field for 30 years.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1365\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141804.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141804.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141804-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141804-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141804-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/> <img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1366\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141810.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141810.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141810-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141810-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251204_141810-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/><\/p>\n<p>That&#8217;s the start.\u00a0 Time to tear it down.\u00a0 I&#8217;ll post later this week about ripping this down to the axle housing and start the differential pinion work.<\/p>\n<p>GO DO SOMETHING AWESOME IN YOUR LIFE.\u00a0 \u00a0CLICK HERE TO READ THE TEAR DOWN!<\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"LV6oXMesy6\"><p><a href=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/4x4\/quadravan-econoline-tear-down-1988\/\">Quadravan Econoline Tear Down 1988<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Quadravan Econoline Tear Down 1988&#8221; &#8212; IDI Online\" src=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/4x4\/quadravan-econoline-tear-down-1988\/embed\/#?secret=OCNpyc4hRX#?secret=LV6oXMesy6\" data-secret=\"LV6oXMesy6\" width=\"600\" height=\"338\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<p>Here&#8217;s the rebuild of the Dana 44 Knuckle.\u00a0 Fun project.\u00a0 Ball Joints are easy with a press.\u00a0 Spindle removals are not easy.<\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"17tfbAH2nz\"><p><a href=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-knuckle-rebuild-ball-joints-shield-repair-spindle-removal\/\">Dana 44 Knuckle Rebuild (Ball Joints, Shield Repair, Spindle Removal)<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Dana 44 Knuckle Rebuild (Ball Joints, Shield Repair, Spindle Removal)&#8221; &#8212; IDI Online\" src=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-knuckle-rebuild-ball-joints-shield-repair-spindle-removal\/embed\/#?secret=E3NvmUet1P#?secret=17tfbAH2nz\" data-secret=\"17tfbAH2nz\" width=\"600\" height=\"338\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<p>Probably the simplest, but most expensive part of this rebuild conversion was the Lockout maintenance.\u00a0 I didn&#8217;t have to replace anything here, but it played a part in the whole Dana 44 disassembly.\u00a0 Check it out:<\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"gE9QhWnZIK\"><p><a href=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-lockout-hub-maintenance\/\">Dana 44 Lockout Hub Maintenance<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Dana 44 Lockout Hub Maintenance&#8221; &#8212; IDI Online\" src=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-lockout-hub-maintenance\/embed\/#?secret=3e1C813RWv#?secret=gE9QhWnZIK\" data-secret=\"gE9QhWnZIK\" width=\"600\" height=\"338\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<p>The big deal with my conversion was matching the 3.55 gear ratio in the rear axle.\u00a0 The donor Dana 44 had a 4.10 ratio, which would not work for me.\u00a0 I needed to swap that out and find a replacement pinion and ring gear.<\/p>\n<p>Nice thing in the process of this was finding Marty at Southern California 4&#215;4, who helped me throughout the whole pinion patterning and sourcing process.\u00a0 \u00a0He had everything I needed.<\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"9KrITkazLT\"><p><a href=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-pinion-gear-exchange-4-10-to-3-55\/\">Dana 44 Pinion Gear Exchange (4.10 to 3.55)<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Dana 44 Pinion Gear Exchange (4.10 to 3.55)&#8221; &#8212; IDI Online\" src=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-pinion-gear-exchange-4-10-to-3-55\/embed\/#?secret=K1GFWCfQRz#?secret=9KrITkazLT\" data-secret=\"9KrITkazLT\" width=\"600\" height=\"338\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<p>While I had the carriage, pinion, and ring gear out, I was able to spruce up the axle housing.\u00a0 First priority, let&#8217;s get those 40-year-old seals out, and get some new ones in.\u00a0 Contrary to what the YouTube says, I needed to use a specific seal that took a bit to find.\u00a0 The details are here:<\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"crhE3kRPct\"><p><a href=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-front-axle-seals\/\">Dana 44 Front Axle Seals<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Dana 44 Front Axle Seals&#8221; &#8212; IDI Online\" src=\"https:\/\/www.nickpisca.com\/diesel\/suspension\/dana-44-front-axle-seals\/embed\/#?secret=14ClgX7sBg#?secret=crhE3kRPct\" data-secret=\"crhE3kRPct\" width=\"600\" height=\"338\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<p>I ended up replacing the pinion seal as well, but it was A HUGE PITA.\u00a0 Ended up cutting the pinion nut, because it was NOT budging.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-1416\" src=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251217_112344.jpg\" alt=\"\" width=\"1235\" height=\"570\" srcset=\"https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251217_112344.jpg 1235w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251217_112344-300x138.jpg 300w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251217_112344-1024x473.jpg 1024w, https:\/\/www.nickpisca.com\/diesel\/wp-content\/uploads\/2026\/01\/20251217_112344-768x354.jpg 768w\" sizes=\"(max-width: 1235px) 100vw, 1235px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>More to come.\u00a0 I&#8217;m getting the old parts off the van today.<\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>I&#8217;m long overdue for some posts to this website.\u00a0 Back in 2021, I got a front Dana 44 axle from&#8230;  <a class=\"excerpt-read-more\" href=\"https:\/\/www.nickpisca.com\/diesel\/engine\/overdrive\/ongoing-quadravan-conversion-project-for-the-diesel-econoline\/\" title=\"Read Ongoing Quadravan Conversion Project for the Diesel Econoline\">Read more &raquo;<\/a><\/p>\n","protected":false},"author":1,"featured_media":1350,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[238,100,177,156],"tags":[],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/posts\/1349"}],"collection":[{"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/comments?post=1349"}],"version-history":[{"count":9,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/posts\/1349\/revisions"}],"predecessor-version":[{"id":1514,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/posts\/1349\/revisions\/1514"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/media\/1350"}],"wp:attachment":[{"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/media?parent=1349"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/categories?post=1349"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.nickpisca.com\/diesel\/wp-json\/wp\/v2\/tags?post=1349"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}