I started looking around the garage for projects to build this winter. I've got a Ford nine inch that I bought a while back and thought about tackling it before it gets warm. My questions are these.

Will this stand up to a 402(may go to a 427) four speed?
What $ range am I looking at to rebuild this rear? It's a 28 spline 3.25 gear open diff. Everything seems to be there(already disassembled when I got it). I'm going to install a locker(probably power trax).
Also I will have to have the spring pads relocated and have it narrowed(going to mini tub eventually).
Any websites, books, or videos or install setup? I'm going to try to setup the gears myself.
Thanks for any help, Jason Hopson

You simply "found" a 9-inch in your garage? Where's your garage?

Yes, you'll likely have to relocate the perches. What car did this come from?

Yes, the 9-inch will handle anything your 402 can throw at it.

Rebuilding costs depend on what all you want to do,..Ring & Pinion? Axles? Posi-carrier?

Figure about 4-5 hours labor, plus parts for a bench job plus a rebuild kit...unless you're rebuilding this yourself?

Well I didn't "just find it", I was looking for odds and ends things to do this wiinter on a relatively cheap budget and thought that this would be something that I could do myself. The axle is out of a Ranchero I believe. The #'s that I was able to get are as follows.
Inside the 3rd memeber C7AW g 18
Outside the third member DIF 64 8J13 (and in a cicrle I found) 6 7 1 3 5
On the pinion DIF 8H16 C6AW 4668A
The overall length of the tube 54 1/4"(outside of flange to outside of flange)
53 3/4 inside to inside.
The spring perches are 2 1/2 wide and are about 3 11/16" from flange.
The inside(diff. side) of the pads are about 15 3/8 from the pumpkin.

What kinda power can a (locked) 28 spline 9 inch handle with factory axle shafts handle?
I will do as much of the work as possible to save on cost. I will probably put a little steeper gear in it(3.73ish).
Would it be cheaper to order new shafts from moser or somewhere than it would be to have mine cut and resplined?
Whatever self help articles or how to's would be great.
Thanks again, Jason Hopson

Sounds like fun!

I just measured a 12-bolt I have 'sittin in my garage' and here are some rough measurements.

From inside brake-plate to brake-plate I measure 53.25 inches. From the center of the perches I measure 42.5". Again, this is rough but will give you an idea of what you're up against.

You mentioned tubbing,..were you gonna relocate the leafs springs?

Lastly,..if you're running a 9-inch, then tubbin' her, why a 402 or 427? Does a 454 grab you,..or a stroked 454?

Smoke'm if you got'em!

If you going to narrow it and get a different carrier go to 31 spline axles a much better deal.

Aftermarket axles are cheap insurance. Go with the 31spline. The 9 inch is plenty strong an aftermarket axles will increase strenth alot.If you're not going to narrow it now, the stock axles should hold up well. You may not have to narrow it to fit your car wth stock springperches, just move the perches, just make sure the pinion yoke isn't ofset alot to one sid as some 9inch;s are.My Firebird has an uncut, 5 lug Dana 60 out of a 68 Bronco under it, all I had to do was move the spring perches. You'll also have to either get a yke that takes th GM u-joint or a combination u-joint to match your driveshaft.

You have opened up a can of worms on this one. There is a lot to cover. First, the 28 spline 9 inch isn't much better than the 10 bolt that you probably have now, because it also has 28 spline axles. If you are going to build a 9 inch don't use 28 spline axles. You will also have to replace the differential, or have it bored out to accept the 31 spline axles. If you are going to use a Lock Right then you will need a set of 31 spline axle gears too.

As for the housing, it will come out to 3/4 inch narrower than a stock Camaro rear end if you don't narrow it. The 54 1/4 housing with 2 1/2 inch axle hang out will come out to 59 1/4 inches. The stock Camaro rear end is 60 inches. If you are going to narrow it then I suggest you sell this one to someone who can use it "as is" and get a 31 spline rear end out of a 4X4 truck. You are going to end up replacing too many parts in this one.

When you start measuring things be sure that you offset the pinion 1/2 inch from center. All rear wheel drive Chevy cars have the pinion offset 1/2 inch to the right, which means that the pinion is 1 inch closer to the right side than the left.

I'm going to stop right there because this could get real long. If you decide to continue with this let me know and I'll tell you what else you need to look out for.

Straight line... As far as moving the spring perches. I'm not sure, I assumed with the mini tub that it was mandatory but I'm a little uncertain as to what goes into mini tubing.(would also like to eventually to a fuel cell and relocate the battery to the trunk). As far as the 40/427 issue that's what I've got so that's what I'll have to work with, but make no mistake if the oppotunity arises to get a good deal on a 454 I'll do it in a heartbeat(but then again I'll have to build everthing accordingly which costs $....more power+more strength=more money) Oh and by the way thanks for the measurements. It sure sounds like this 9" is aweful close to the same dimensions.

69X11...thanks for the info about the dana 60. I'll take a closer look at some older Broncos. I know where some are setting, I just figured they had 9's or 44's. Had no idea they were equipped with 60's. How much did you give for yours if you don't mind me asking?

BGH....Why will I have to bore the tubes for a 31 spline axle? I just assumed(again I'm assuming) they were all interchangable. About the lock right. I'm not set on a lunch box, what if I find a factory posi unit for 28 splines(maybe trade up a little with what I got). Would having a shorter than stock axle play to my advantage or work against me? What would the setup that Ive got right now be able to handle if I assembled it as is plus a posi/locker? And lastly. What are 44's able to handle?

Thanks again for all the help.

You don't have to bore the axle tubes. There is a hole in each end of the differential case (carrier) where the axles go through. The 28 spline differential has a smaller hole in it than the 31 spline differential. A 31 spline axle will not go through the 28 spline hole, so it has to be bored out. If you stay with the 28 spline axles then you won't have much more strength than a 10 bolt. As for the length, the resplined axles are weaker than uncut axles.

The factory limited slip differential (posi) is a Traction Lock. They are not very strong. Ford cut the strength of the differential when they cut material out of the side cover to make room for the clutch plates. They break very easily. US Strange makes a Traction Lock with a steel side cover that is stronger than the Ford unit. The Detroit Locker is the best.

I have never seen a Bronco with a Dana 60 in it. I have seen them with Dana 44s. The strength of the 44 is about the same as the 8.5 Chevy 10 bolt. Both have a 8 1/2 inch ring gear.

Yea, my Dana60 puzzled me when I first got it. The spring pads were on top of the axle tubes and it hed the funky truck shock munts on it. So I knew it was out of a truck but was too narrow for a full size. The 5x5.5 bolt circle axles didn't help figure it out. Also the pumpkin does not had the porvisions for a pinion snubber, so it didn't come from a car. Also it had standard Ford drum brakes and large Ford housing ends. All this was factory on this rear end and had a 1968 date code. Since it had Ford ends and brakes, I took the numbers to a Ford dealer for ID and they told me it was out of an early Bronco. I found mine on the grond of a junkyard and gave $150 for it with an extra locker (but that was 15-16 years ago). These have very stout 30 spline axles and aggressive lockers in them.As far as your stock 9inch axles, while they aren't as strong as a 31 spline, I've never seen one that was as weak as a 10 bolt rear.The GM axles are thin and are larger in diameter at the splines,that's what makes them weak. Alot of the 9 in. axles are th same diameter all the way to the splines, that's not to say they didn't make them just like the GM axles, just that I've never personally seen them.If you have a 67-69 Camaro with a 10 bolt, that is an 8.2 and a stock 9 inch is worlds better than that reared.If you buy an aftermarket posi for your 9inch, just specify it's for 31 spline axles then get a set from moser and you'll be good to go. If your unsure how to measure your axles for replacement, just do what I did, call Moser and send them your old axles and they'll copy them for you with any modifications you need made. Also, it is betterto go with new axles instead of resplined.

Thanks for the feedback everybody. I'll check with Moser and see what I come up with. If nothing else I'll have a backup if something ever happens to one or the other.

I don't think the Bronco ever used a 60 but the 68 1/2 ton full size Ford truck did. As you discovered it a little different from most 60s. I really liked the thing in a truck especially with the really good posi.