'01 Explorer ST, Coil Sprung 4-link d44 front, d44 SOA Rear

Starting my build.. Officially Im about a month from pulling it into the garage..
The parts and modifications will be accompanied with photos as the build progresses..

As the title suggests I am using '87 Jeep Grand Wagoneer Dana 44s, as the donor axle for the project..
The Sport Trac is a 2001 Job 1..

 

[Tif0ez]

Putting the rear axle under the springs for a starting height for the rear, will adjust with added leaf springs..https://scontent.***c1-2.fna.fbcdn.net/v/t1.0-9/15492123_125656661257051_6348237114956643564_n.jpg?oh=a5ecfde92161d912a02129d6ecb852ea&oe=58DA4C8F

https://scontent.***c1-2.fna.fbcdn.net/v/t1.0-9/16105796_156421364847247_404392844799534870_n.jpg?oh=b87392a09d25fdaad8ab533110b6573d&oe=590FF9E8

 

[Tif0ez]

Starting with an open engine bay will give me a closer look at the modifications for the Dana 30
https://scontent.***c1-2.fna.fbcdn.net/v/t1.0-9/15977240_156422954847088_3033201742095827654_n.jpg?oh=08d9abd8a33926857e68370f026e3e1e&oe=58D93597
Will be unbolting and removing as much as needed to hang the coil spring perches
https://scontent.***c1-2.fna.fbcdn.net/v/t1.0-9/15965579_156422824847101_4150364399826489586_n.jpg?oh=b106757e2b3ee762ed84ec92b8fac796&oe=58DE707B
This is the starting point, a 2000 Jeep Cherokee Dana 30 with a long arm lift..
https://scontent.***c1-2.fna.fbcdn.net/v/t1.0-9/16002867_156422891513761_3822445593857048093_n.jpg?oh=c9c479b52bbda185bce50ae317208000&oe=59230B42

 

[Tif0ez]

Sat the motor on the mounts today, had to pull the Trac out for a transmission job.. Will have to raise the motor when it comes back in, I want to replace the oil pan, and clean up the block for paint.. I also want to clean up the engine bay, cleaning and painting while empty, then rerouting wiring and hoses for a cleaner look.. I don't have any pictures since I didn't actually do anything, but wanted to post an update.. I am aiming to have this build done for the All Ford Nationals during the first weekend in June..
Income tax is due in, and parts are being researched.. Eye candy pics to come within the month.. Stay tuned!!

 

[Tif0ez]

Running a little behind, but we are going to attempt to have this build done for Carlisle 2017.. Started cutting the fat from the front to make room for the Dana 30.. I am already looking into Dana 44s but that is an upgrade for a later thread..
Anyhow, wanted to put up some pics..
https://scontent.***c1-1.fna.fbcdn.net/v/t1.0-9/17862519_795344313957615_7355498051486395753_n.jpg?oh=26d643634063a6edfe339158156b6540&oe=598C654B

"after we cut, there is NO going back!!"
https://scontent.***c1-1.fna.fbcdn.net/v/t1.0-9/17861858_795344287290951_126208586653165308_n.jpg?oh=d303b29d29df5244498f6e60be9bd96d&oe=598DC085

Taking off the unwanted weight..
https://scontent.***c1-1.fna.fbcdn.net/v/t1.0-9/17799110_795344273957619_1029184540534984476_n.jpg?oh=18beb217c2f08fb3b25807b03d0e5320&oe=599423FE hello m'luv!!

Things are heating up with the push to get done to go to Carlisle so we can finally meet our neighboring Serious Explorers!!

 

[Tif0ez]

So we have a new addition to our garage, an '02 ST, clean, and for $500.. This thing is cleaner than my project truck, so it's our dd and now we can go excessive with Dreamcatcher..
Well, since we missed Carlisle 2017, I've yanked the '87 Grand Wagoneer Dana 44 axles from the heep, and project is gonna be big....
I'll still be soa in the rear, but the front will be 4-link'd..
Both axles are "Yukon locked" but I am unsure of what is in the dif until I break them down..
Both front and rear axle are set up for the 4-link, so at this stage I'm simply adding mounts to my frame..
We had a long talk on how to put all of this together, the angles, and how to deal with the hulking "u brace" crossmember that'll be inches from the upper 4-link heim gusset..
So wish me luck on the most exciting part of my build..

Might eventually become 4-link'd in the rear, but for now it'll stay leaf sprung..
https://scontent.***c1-2.fna.fbcdn.net/v/t31.0-8/fr/cp0/e15/q65/20116839_848485348643511_1564534086998863576_o.jpg?efg=eyJpIjoidCJ9&oh=c5b3aa463690aed1e69d1ba0f6c05f4c&oe=59F0A3F6

Front mock-up..
https://scontent.***c1-2.fna.fbcdn.net/v/t31.0-8/fr/cp0/e15/q65/19983257_848485301976849_8198513128222322636_o.jpg?efg=eyJpIjoidCJ9&oh=5e2fd060c140a122a74f458a169ef018&oe=59F38BF5

 

[Tif0ez]

So I've heard that it is possible to use a first generation explorer 4.0 manual transfer case and bolts up to the second Gen 5r55e??
Thanks in advance..
So close I can daydream driving her..

 

[Tif0ez]

https://scontent.***c1-2.fna.fbcdn.net/v/t31.0-8/fr/cp0/e15/q65/20449210_855857521239627_8345522292889195599_o.jpg?efg=eyJpIjoidCJ9&oh=d2df1ab041f4a7864bbf5a56b768613c&oe=59F8C095 Progress, fitted the lower 4-link mounts, welding them in Friday..

 

[Tif0ez]

wow I have a lot to update..

 

[BKennedy]

I think the T-cases bolt up, but am not positive.

If you are using Jeep axles, you could find yourself a set of used long arms and save a lot of time fabricating.

 

[Tif0ez]

I'm currently at this, but I just noticed all the links for the photos are screw'd so hopefully I'll updatell and fill in the missing pieces..
I wish I had someone to just randomly take pictures, and while jammin and wrenchin I never think to stop and take one..
I do have plenty of pictures, we all know the explorer frame, so from everything I have, I'm almost positive I can show-n-tell what is where and why..

I still have a long list of medium and little details to fill in, this might honestly turn into the "editing prebuild thread" thread.. That way I can do a start to finish thread with more detail and upload all the pictures so I am unable to change the location (to clean up my Facebook page) and then the photos here end up with broken links, and unable to be viewed..
Sorry again for my lack of forum and thread skills, I'm slowly gettin there

 

[Tif0ez]

Due to another family situation, we've moved 20 minutes away from home & shop.. This temporary move will last around three months, so we decided to bring the project with us.. It'll be easier to spend a few moments working on it here, so I can focus on important tasks at the shop..

I still need to add details of the axle design change, and how I cut and modified the frame and added in the 4-link, if anyone has questions, please feel free to direct message me, and I'll pass along the info and photos..

Once I have the entire build together in one place I'll finally be adding a complete build thread to tidy up my content Should prove to be an adventure in itself, stay tuned..

 

[Tif0ez]

Ok, so, not much to report at this time.. I was able to remove the rusted bolts from the exhaust manifolds, and throw them on the motor without gaskets in a temporary mock-up for how I will run the exhaust system.. I do plan on attempting to make this street legal, only to be able to park it in a space at our home.. Since both front and rear axles are full spooled it'll never see actual street use.. Uh.. I did have a first start video and somehow my phone managed to eat it, so I'll grab a "present day" start.. Maybe y'all can diagnose if the random rev, and needing to "give it pedal" to keep it at idle, is due to headers only, or if I have an issue with a faulty throttle positioning sensor..
https://scontent.***c1-2.fna.fbcdn.net/v/t1.0-9/47296367_1162427980582578_6143092745671016448_n.jpg?_nc_cat=100&_nc_ht=scontent.***c1-2.fna&oh=047330c0862cd146109e089cf4f80522&oe=5CAB8B1C
At this stage of research and development I have found an issue with clearance on the 4-link and the oil pan, so to solve this issue I'll be looking into taller springs for the front, and set the rear to match.. I'd also like to relocate the steering box to solve the extreme angle of the drag link as it'll only get worse when it goes higher..

I'll be looking for a new front bumper cover, or another Rough Country aftermarket Jeep Cherokee winch bumper that I had at one point & was able to mount up and have a decent appearance, but too high for local laws in my opinion.. From this picture I actually have to say I love how the stock '02 5.0 project looks with the push bar, so until I commit to something else, I'll be shooting to make them twins..
One close to stock with 2nd weight class tag that is getting a 5.0 swap, f-250 brake booster & master cyl mod with all new brake lines, heavier tire & wheel combo, & rear spring rework..
Her stupid lifted sister will eventually get the 5.0 if needed, the f-250 mods and will continue with the theme..
https://scontent.***c1-1.fna.fbcdn.net/v/t1.0-9/46819115_1159424384216271_5734565012777730048_n.jpg?_nc_cat=110&_nc_ht=scontent.***c1-1.fna&oh=57644929912a36feeaea649c0ebf417f&oe=5CAEA2EA



Connecting the 4.0 driveshaft to the Dana 44 is at this point a "one-off" where I am using the '01 flange on the '87 44 yoke
https://scontent.***c1-1.fna.fbcdn.net/v/t1.0-9/43043459_1126049144220462_7569270536484683776_n.jpg?_nc_cat=110&_nc_ht=scontent.***c1-1.fna&oh=362d60f70189409c9add66e70d9847c5&oe=5C63612B

The above picture is mocking it to check where the mounting bolts will need to go..

The below picture is the u-joint to yoke, you can see the tooled areas that I have worked so the bolts for the yoke will sit flat.. I'd like to go with a larger size grade 8 bolt, but the yoke on the 44 doesn't have the space so the oem size grade 8 will be tested..
This connection may end up welded at some point if the bolts fail on a regular basis..
https://scontent.***c1-1.fna.fbcdn.net/v/t1.0-9/47390875_1162449440580432_2259522534250643456_n.jpg?_nc_cat=101&_nc_ht=scontent.***c1-1.fna&oh=97c692ce470c52490eacda5774275d42&oe=5C6D3DC6

I am also making every attempt to fabricate a true dual mirrored exhaust system that wont affect clearance, and be heat shielded in sensitive areas.. sorry, no pictures of this yet, still a concept in my head..

I'll keep y'all posted, and I hope everyone had/has Happy Holidays, a Merry Christmas, & a safe New Year!!
(I'm horrible with "keeping in touch, and sending Holiday messages", so I cheated and bunched them together..

 

[410Fortune]

Very nice!!

Cant you just use a conversion U joint at the flange?
I love the spot tracs man keep these threads coming!

 

[justgetinstarte]

I have to advise on the ujoints don't stack them liken that. It's very dangerous. Take the pinion nut off and just change it out it will be safer and takes about as much time. They make pinion yokes in all sizes so u should be able to find one.

 

[BKennedy]

I also don't like your U-joint modification. There is no way to get it balanced and there are all kinds of yokes that will work. My 1310 yoke from my transfer case bolted right up to my double cardan joint on the drive shaft. Same drive shaft worked for my OEM transfer case, to the NP231 and from the TTB D35 to my HP D44.

 

[Tif0ez]

I have to advise on the ujoints don't stack them liken that. It's very dangerous. Take the pinion nut off and just change it out it will be safer and takes about as much time. They make pinion yokes in all sizes so u should be able to find one.

Honestly this mod is only to make it movable under her own power while building.. Using chains to tow it around is getting old..
This mod is only temporary, and at some point I already believe that I'll be looking into something custom regardless, to clear the oil pan the front needs to go up another 4 inches, and the rear will get taller to match, changing the distance between the tcase and the yoke, yet again..