Solid Axle Swap Registry | Page 7 | 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
1992 XLT Well, I think I was second on this board to swap a 44 under my rig, behind Rick. '79 Bronco Dana 44: - housing cut 6" - pulled out longside tube from outer, cut 6" and press back on and weld - axle shaft cut 6" at LeJeune engineering in Victoria, BC - cut, tapered, and tig welded in the middle of the shaft - no problems - tierod cut down 6" and rethreaded - drag link cut and threaded to accept my Dana 35 TRE and adjusting sleeve - Dana 35 TRE used at pitman arm - coil buckets modified to accept James Duff 3.5" VR coils for EB - stock radius arms - '79 Bronco radius arm brackets - new Dutchman 1541 Alloy rear shafts for my 8.8" for 5 on 5.5" bolt pattern new this week: - '79 housing cut down 3" - BC Bronco...
Kind of new to the forum. Signed up a while back but haven't posted much. Explorer specs. mostly stock 4.0, built A4LD, manual 1354, HP44 front, 9" rear. Front has 5.13's, ARB, high steer. Rear is detroited, 5.14's with a currie case, disk brakes with caddi calipers. 4" custom Alcan leafs in the rear. 5.5" BC bronco's EB springs in the front with custom coil buckets. 1 ton drag link end steering. AC pump converted to on board air run to rear bumper. Tires are 36x12.5x15" TSL SX's. I don't have a whole lot of pics of it. I usually go by myself and I don't have a camera. This winter it's getting a 5.0 HO swap, AOD to NP208, HP 60 front with the same gears and locker as now, and a dana 70 rear with...
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...
91 Explorer Solid Axle Swap Hello everyone. This is a White 91 Explorer. Solid axle came out of an 89 jeep wrangler. Front leafs are new but from a jeep. The rear lift was made by using high arched "soft ride" leafs, and flipping over the axle. There are not any blocks! The front has 12 inch Fox shocks and resevoirs (though resevoirs are not in pictures, i am getting them installed this week. Iwill get new pictures as soon as that is done.) The Truck Has 37" Super Swampers SSR's on it right now but i will be putting 38" Tires on it when these wear out. I still have to measure it next to another but i believe the total suspension lift is about 15 inches plus the tire difference. The frame is 29" off the ground...
I have officially finished the SAS and have driven it to and from work a few times successfully with no real problems, so I will consider this stage complete. FRONT: 1978 F-250 Dana 44 HP Sky Manufacturing high steer arms Hydro-assist steering 1990-ish Astro Van steering gear box drilled and tapped for the hydro-assist Custom front cross member Custom rear hangers E-bay boomerang shackles H1 double beadlock wheels 37x12.5x16.5 BFG Baja military tires Stock 4.10 gears (Puke) <--- Will be upgraded when I get the money Rear: 1978 F-250 Dana 60 1980-ish Chevy K20 disk brake conversion Stock leaf springs hangers etc. Matching 4.10 gears That's what I can think of worth mentioning off the top of my head. The link to the build is in my...
A little planning and 4 months later, my Sport Trac finally has a solid axle in the front. Current Look: Front Axle - Low Pinion Dana 44 from a 1988 Grand Wagoneer - 6x5.5 bolt pattern - 4.88 gears (still open diff for now) - Superwinch manual hubs - Disc brakes - Custom spindles tapped for hi-steer - Custom 1.5"x.25" wall DOM drag link and tie rod - Stock Grand Wagoneer 7leaf pack flipped to SOA - Bilstein 5100 shocks (originally for Jeep JK with 6" lift) - Ford Super Duty steering box (pre-drilled for hydro-assist in the future) - Drop pitman arm for Super Duty with 4" lift - Front stainless brake lines for stock Jeep TJ - Custom sway bar end links - New Moog ball joints and bushings - Grand Wagoneer track bar mounted to frame rail
I started out with a 01 explorer sport with 230k miles and now i have a 2001 frame with axles out of a late 80 f350 2003 body with 90k on it with stock drivetrain (for now). My plan is to either build the drivetrain i have now (4.0 sohc with a 5rod) or go to an lq4 engine and then 4 link it front and rear with coil overs within the next year or two. I will try to list all the parts i used but i know i will miss some so if there are any questions please ask. The swap has been one for about 8 months and i have put about 15,000 miles on it without a hiccup. No sway bars, trac bars or even a steering stabilizer (plan on doing a stabilizer before winter). This is my winter vehicle (for now) so i have my car i daily and drive my exploder on...
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...
Hi there. Last year I bought this $600 beauty. This November i turned it into this beast. Last spring i did the BW4406 transfer case swap to be done with the AWD poo. Then i spent the summer collecting parts, narrowing the front axle and getting the gears set up. The list. Factory v8 212,000 miles on the clock. '78 bronco HP dana 44 narrowed 6" completely rebuilt Chromoly early bronco shaft's Detroit locker front 4.56 gears Custom long radius arms Wild Horses 3.5" coil springs Rancho rs 9000's F/R Thunderbird calipers Gen 1 explorer front shaft modified. Inverted chevy tie rod ends, 1 1/2" tie rods Bronco2 steering gear rebuilt and tapped for ram assist BW4406 transfer case Original 8.8 completely rebuilt during SOA Welded center...
Well since I don't have the time/tools/skills to build my own, but I do have the money, this isn't going to be a build log, just show the final product since I don't have much for "during" pics. Dana 30, trussed and gussetted. 4.56 gears, Eaton Truetrac (front and rear), SOA with Chevy 1500 63" leafs, 1354 manual transfer case, F-150 steering box.
Hey all, don't know why I took so long to officially register it, maybe because It will never really be done, but anyway has been officially SAS'd for a while so here it is. The axles were from a 78 (79?) F-150 -I`d like to give special thanks to the great members and organizer's of this site for input, info and support over the years. Thanks for the stimulating conversations as well. Rick, thanks for turning me on to my addiction. Thanks anyone involved for allowing me to go to Moab with y'all in '04, actually while I think of it thanks again Jefe for helping me get my coil back in on the trail in Moab. Have I got everyone? Too many to list - You know who you are!Thanks to my wife for not complaining too much over all the money I...
So I had a EB D44/9" combo and some 33" Super Swamper LTB's, but then my friend had these axles for sale. Now I have a D60 and a D70. The 60 is low pinion, but is king pin. Gears ar 4.10's for now, 5.13's are in the future. Rear D70 has Discs added. Tires are 36x13.5x16 Iroks Front springs are 6.5" BC Bronco coils. Using modified late '70's F150 buckets. Rear is spring over with a 1" 0 rate. I will add some shackles to level it out soon. Here is a pic: In that pic one side is still on a jackstand and higher than with the tire, so the front is actually a bit lower now. I will get more pictures later, but I have beenbusy working on it! Here is a before pic:
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