Solid Axle Swap Registry | Page 3 | Ford Explorer Forums - Serious Explorations

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Solid Axle Swap Registry

If you have completed a solid axle swap on your Explorer and would like to share the results with others this is the place to do it:D This isn't the place to talk about a work in progress, rather a place for the FINAL results, specs, instructions etc
This was a buddie/customer build I recently did, I look at it as practice. My wife has a 98 XLT V8 explorer and in the spring shes getting a D30 and 33's. Run down on this build..... 1995 Explorer sport 4.0L m5ord and 1350 (eventually auto of some sort and most likely a 1354) 78/9 D44 5.13's Aussie, old school yukons (the good ones) with ctms 9" with 5.13 and spool 38.5x14x15 TSL's on Beadlocks (my old locks I built years ago) Radius Arm front with EB coils, maybe an 78/9 steering box (maybe) Before Pic, who's straight,clean ranger is that? Looks similar to Kyles beat and dented ranger:sonicjay: Got the old 8.8 out and a 9" in position. temporary on the mono leaf. Plan to change that later. But needed to get...
For my 10,000th post I guess I will start my SAS registry now that the truck is done. :thumbsup: Section525's SAS Build thread Specifications Front '83 Wagoneer LP D44 JCW 5-leaf Springs (Stockers) Detroit EZ Locker Spicer 4.88 gears Warn Premium Hubs Rock Equipment Super Boy Howdy Fabricated Knuckles Sky Manufacturing High-steer arms Pro Comp MX6 Shocks Rear Stock 8.8 SOA Sierra 4.88 gears Detroit EZ Spidertrax 5x4.5 to 5x5.5 adapters Stock shocks The Build The LP D44 came out of a 1983 Jeep Wagoneer. I was there when the guy pulled it out from under the Jeep. It was nice to see the condition of the donor before buying the axle. I began the tear-down of the axle and everything looked good inside. :cool: I used TT Fab...
EEE's Solid Axle Swap #1 Shortly after returning from Moab, Utah in the Summer of 2001, I decided that I was going to bite the bullet and go with a solid axle swap, or live axle conversion. The 1991-1994 Ford Explorers were equipped with Dana 35 TTB, or Twin Traction Beam, suspensions, that, in my opinion, leave much to be desired. The pivot points in the middle of the TTB are flex-killers; and if you have any plans of doing any serious rockcrawling, the TTB has to go. The Dana 35 is also equipped with weak aluminum bearing caps. With that said, the solid axle swap provides other benefits besides just flex and articulation. It also provides superior strength, more stability, and tends to stay in alignment much more so than any...
Ok - after about 4 months of planning and tinkering, Tramp is out! Details: 4.56's Detroit rear, EZ Locker front 37" Goodyear MT/R's 1.25" spacers that convert the rear to 5x5.5 D44 from a '75 bronco James Duff coils, shocks, RA mounts F150 outers up front Steering by CoryL Customs This project was a huge undertaking. I started with a stock '93, added 31's, then a 3" bodylift, then a 5.5" superlift and 35" Xterrains. After too many issues with the front end, I decided to swap. Bought all the parts I needed, but ran into many problems along the way. From brake lines to transmission crossmember, they cam about once per week. Here is a pic of the crossmember cut and braced... I have since added a 45 degree brace...
Finally got Some pictures, so I can finally do my write-up. Here is the Specs Axle: 76 F150 High Pinion Dana 44- This year has the 1/2" Axle Tubes Like a Dana 60 Narrowed 6" off Passenger side Passenger side Axle Shaft resplined by Dutchman Motorsports http://dutchmanms.com/ New: All Seals, Calipers, Pads, turned the Rotors, Spicer Ball Joints, SPicer U- Joints Warn Premium Manual Hubs Warn Diff Cover (not pictured) 4.56 Gears Open Carrier For Now Before Pics (3" VR James Duff lift 235s) Middle Before SAS (33x10.50 ATs, 4.5" Lift (3" VR James Duff+ Spacers and rear Spring over), Extended James Duff Arms) Steering: I purchased all the Steering link parts from RockWare (http://www.rockware.net/) 4 3/4" Heim...
k guys here how it went..... front end: hp dana 44 (from 79 f150) rear 4 in lift springs from the f150, but we took out 2 leafs... used steering from the f150 moved the axle forward 3 inches... rear end: ford 9in from same truck moved the axle back 3 inches... it turned out real good, all we need to do is get driveshafts which will be done tomorow.... will post pics tomorow when i drive it home:)
The SAS has been complete for some time now so it is time to complete a registry. It is a daily driver for now and it has seen trips to Badlands and is getting ready to go to www.woolysoffroad.com. Didn’t turn out to bad……. Spec: Front end: 1978 F-150 HP D44 4.88 Gearing Warn Hubs Stock Brakes Custom Track Bar Mount Custom Coil Bucket Mounts 7* C-Wedges Wild Horses 5.5inch Rock Crawler Coils 78 F-150 Coil Buckets and Shock Towers Wild Horse Extreme Radius Arms (12” longer than stock arms) Rear Axle: 1978 F-150 9" 4.88 Gearing Spring over 4"block Shocks: BDS Extras: Nick's Driveline Custom rear drive shaft Custom front bumper W/Atlas Winch 5 Speed Swap Rear Bumper with reciever...
so after a long time, money burning a hole in my pocket, and the devil on my shoulder..I went ahead and cut up my explorer. I started out with 2 dana 60's..one was a full float with brackets, 4.10's and stupid drum brakes. I went ahead and took the ring and pinion out of that and set the rest aside for a rainy day. Then I got my dana 60 housing, which is a semi float 5x5.5 pattern axle with no brackets, carrier, or gears. i rebuilt the whole thing and stuffed in the gears. after that part was all finished, I went out and got a set of ballistic fab GM caliper brackets and calipers, also I got the old axle out and thrown aside Then the new axle was all ready to be put in..so I switched the springs around in the rear to give me a little...
Here is the link to my car domain site. http://www.cardomain.com/ride/2209152 It has been a long three year process reasearching, building, and collecting. I still have a few things to decide on like shocks and my explorer axle swap on the back. I am just ready to take er out and drive it. I will post more pics of the suspension and crossmember and hopefully some action shots later. I welcome all questions and comments. This site is awesome and it would have been alot harder to accomplish without it.
Daemon's SAS *updated 17 July* Front: -'79 Bronco 1/2 ton HP Dana 44 -narrowed 5 3/8" on the pass side -moser alloy shaft on the passenger side, and stock shafts on the driver side. :) -CTM u-joints -5.13 gears and No-Spin Detroit -WH 5.5 coils -1.5 x .25 wall DOM steering links using tube inserts, and 3/4" heim joints -superlift adjustable track bar -stock bronco radius arms with 7 degree bushings -cut down bronco coil towers and F-250 shock towers -RS 9012X shocks. Rear: -'79 Ford 9" -disk brakes -Dutchman alloy axles -5.13 gears and Detroit -2" OME leafs SOA -RS9000 shocks Tires and wheels: -15x8 rockcrawlers wih 2.5" BS -37x12.5 Super Swamper SSR radials*
I completed my sas and soa setup on my 00 mountaineer. Front axle is a wagoneer Dana 44 with new wagoneer leafs up front. Steering is handled by a Toyota steering box mounted outside the frame. The first test drive was extremely disappointing. The truck drove terrible and the bump steer was uncontrollable. I added a track bar which helped the bump steer some, but over 30mph it was still totally dangerous. Took it to a shop to get aligned. They said the caster was off 5degrees and that is causing the poor handling. I ordered a pair of axle shims and put them in before attempting to rotate the knuckles. Even with the shims it still drives terrible. It darts around the entire time and if you hit a bump, you never know what way it's going...
Well I guess I should do this thread now sense my SAS is done now. Wow never thought I'd say thouse words. So here's how it turned out. Here are the spec's Front Axle 79 Bronco - Dana 44 High Pinion Yukon 5.13 Gears BTF 44 cover Spicer u-joints Warn Hubs 78 Thunderbird Calipers Superlift FSB track bar cut down Custom tie rod's from 1 1/4" DOM, 1/4"wall Chevy 1 ton TRE's 7* C-wedges (need to go to 4*) Wild Horse 5.5" Rock Crawler coils BBCS 15" Shocks Early Bronco Coil Buckets Custom 48" long Radius Arms Modifed Bronco RA mounts Russell brake lines First gen Explorer steering box First gen Explorer steering shaft Rear Axle 89 Bronco 8.8 Yukon 5.13 gears BTF 8.8 Cover Powertrax No-Slip locker Currie...
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