You asked for advice, everyone told you to wait and get a D60, you're dead set on downgrading axles because you want a solid axle, I get it. I am feeling generous because I've been an ******* lately so here you go.
your 78 D44 is 68" wide, your current front axle is 69.25" wide, you need to be aware of this, it will be noticable.
the spring pad width on the 78 axle will be 31.5", your truck is 36".
the 78 axle has a cast in spring plate on the driver side, this is ok because you are moving it over 2.25"
first, purchase 3" wide leaf spring pads, then cut the passenger pad off of the 78 axle. pull TTB out of your truck, set 78 axle under it with spring pads on, lightly tigthen the u-bolts enough to take up all slack, but still able to rotate axle tubes. set axle down with jackstands under it. I dont know what type of front d-shaft you have.... so
if its a CV shaft, the joint at the axle needs to be at 1*, if it is just a 2 joint shaft, do your best to match the angles at both ends. Once you have made sure you have the d-shaft angle correct, (dont worry about castor, it will be fine on your setup) and that the axle is still centered, tac weld the pads on.
pull axle out... fully weld pads on, bolt axle up.
steering is stupid simple, but you're stuck spending a little bit of money because your steering box is wrong to run the 78 F250 setup, and the F250 axle is 2" wider than the F150 axle which uses the same steer setup as you.
have fun.
thats good right there
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