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
 
FullFootNotch's SAS on 38s 1992 explorer sport 4.0 5spd Engine mods -K&N flat filter -Flowmaster Single Exhuast -Gutted Cat -Ceramic Clutch 4dr Auto tranny metal radiator, for betting cooling and to get metal endtanks, and same size and everything for the manual even though its an auto tranny rad, so built in cooler for anything in the future Exterior mods -Custom fade clearcoat- fades from clearcoat to no clearcoat in a few inches -Factory manual sunroof -Cheap black front push bar -Smittybuilt nerf bars -Smittybuilt Tube rear bumper w/ 2 inch receiver -Passion purple tint-patent pending of course -Flat black rustoleum on rear pillars Suspension -NO B/L -SAS’d front -Dana 30 front, stock gears -Pro comp 4 inch 73-87 front chevy...
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*
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...
Just got the straight axe in this weekend. Pics coming soon but I'll give you the skinny on the swap. Pulled the ttb friday after work. Set up the axle welded front and rear mounts. and had weight on the axle saturaday. Sunday brakes and steering and tighten every thing. Along with first road test which resulted in sloppy steering which is fixed by a sleeve in the steering knuckle D30 ( out of Xj): $200 Grand wagoner steering: $25 Xj rear leafs: freebie fixed front mounts: $50 8" buggy spring to shackel rear mount: Freebie Soa: $20 rotors and brake pads: $45 wheel base extended 1" To 2" waiting on 6" Xj leafs which will sit about 4" Custom front shock towers It's not pretty but it's going to get the job done
Got Flex? :D Dead Link Removed Setup consists of: Front: Rubicon Express Long Arms for TJ's Custom D44 front axle: -High Pinion -4.88's -Elec-trac -TJ width (~2" wider than stock explorer) -TJ brackets -Chevy outers; 11" disk brakes, Warn premium hubs, 5x5.5 bolt pattern Sway-a-way RaceRunner coil-overs: -2" reservoir, 14" travel shock -dual rate Eibach springs; 250, 300 1st gen. steering gear box -hybrid steering shaft Custom steering links -1 1/4" .120 Chromoly -3/4" heims Rear: SOA Stock leaf springs (for now) Warrior shackle MORE wheel spacers: -1" spacer -5x4.5 to 5x5.5 conversion A few of the test runs: Dead Link Removed Dead Link Removed Last Chance...
It's the moment you've all been waiting for. It's not totally done all the way, but we just have minor things to do. What's left is: Rear brakes, attach front driveshaft, move the axle forward maybe 1-2", more welding, put Cory's steering on, then shocks. This should take less than a day to do. '76 EB D44 '76 EB 9" 35/12.50R15 BFG MT's 15x10 Rockcrawlers Coils from James Duff James duff extended radius arms Front and rear ARB's 4.56 gearing RS9000X shocks steering from CoryL Here are the new coils. They worked perfectly. I'll have more pics as the rest of everything gets together. I'll paint everything later too. Here are previous pics of the build up: My old axle...
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...
Completed! Specs: 1997 Ford Explorer Sport 4x4 SOHC 4.88 Gearing 35" Procomp Xterrains on 15x10 Black Rockcrawlers Rear Stock Axle SOA Extra Leafs to Match Front Height 5 on 4.5 to 5 on 5.5 wheel adapters from Performance Wheel and Tire Powertrax No-Slip Front 1976 Bronco Dana 44 Lockright Locker Stock EB radius arm - Passenger side wristed 7* Radius Arm Bushings Wild Horses 3.5" VR Coils Dual Shock Setup with Explorer Procomp ES3000 shocks F-250 Shock Mounts Custom Radius Arm Brackets CRL Customs Bigg Dawg Steering Ford Ranger Steering Box Drop Pitman Arm Before (4" Suplerlift):
A friend and I completed this swap in four days, which is a good thing considering this is my daily driver. Here's a quick run down of the mods to the front end: -'71 EB D44 sandblasted and powder coated -4.56 gears w/ ARB -3/4 ton chebby inner shafts w/ '78 bronco outers (297 U-joints) -chebby disc brake swap -3.5" wildhorse springs -F-250 shock mounts w/ RS5000 shocks -custom steering using 1-3/8" D.O.M tubing 5/16" wall w/ full size chebby TRE's -'76 f-150 coil buckets -skyjacker radius arm mount (it was already on the truck) __________________ Pictures
Solid axle Navajo.. I did my Navajo in early 2001. My chain of events was: installed ARB in front d35. Blew ARB up after using 2 times. When ARB was pulled, and a open diff was installed, bearing caps on d35 pumpkin broke. Decided enough was enough - I also had a Superlift 5.5" lift on it, and was breaking/bending brackets every few months. Pull the navajo into the back of a local shop, and started cutting off the TTB components. We cut 6" off a 1979 Bronco D44, from the passenger side (long tube side). Sent axle to Dutchman for cutting down. Also bought 5x5.5" pattern axles for the rear 8.8, and upgraded to disk brakes at the same time. Rear was running the Superlift SOA kit, which gives 5.5" of lift. Added 2" more lift...
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