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1998 Sport D-44 SAS Complete!!!

Discussion in 'Solid Axle Swap Registry' started by Skunk, March 5, 2003.

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    1. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      I used a regular set of pirches, however, I used a grinder to grind the drivers side pirch to fit the casing, you will also need to grind the bottom, were the pirch was factory so the U bolts will fit around it. I dont know how experienced you are with welding, but when you weld the prich to the cast casing on the drivers side, be sure to get it either mig'ed by a big ass welder, or if your using a stick welder, use Ni-Rod.

      Now, as per $810 for those parts, HOLY $H!T!!!!

      they are maybe $200 at the most.... you may want to think about a trip to Harrys you pull it, out here, parts are so damn cheap. dont dare spend $810 on those parts!!
       
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    3. cdsl227

      cdsl227 Elite Explorer

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      Thanks!

      I was leaning toward buying the F-150 ($500) axle and pulling what I need off that.

      I was hoping to get SOA perches that were designed for that axle...but if I gotta grind some... :D Oh well...

      My friend owes me a favor so he is going to give me his 220 Lincoln Arc and run a 220 outlet for me. He never uses it anyway...and complains it's taking up space.

      At least now I know what sticks to use.

      What size is the box tube you used in the front...I'm guessing 4"x4"? That's not DOM, right...it's seamed...that's all I can find here is seamed box tube.

      When it comes to looking for parts- DAMN IT S#CKs to be in NYC!
       
    4. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      out here you can pick up a f250 front end for less then then half of 500

      yeah, make sure you use Ni-rod for the steel to cast welds, you dont need it for steel to steel tho, just a good 7018 rod will work fine.

      the front tube is actually a class 3 trailer hitch cut down with 1/4 plating for the front spring mounts.
       
    5. cdsl227

      cdsl227 Elite Explorer

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      Quick question-

      How did you measure for locating the front spring mounts?

      I'm assuming spring length eye-to-eye split somewhere down the middle...

      I'm curious how you got the axle positioned correctly...

      I figure if I get 2 or 3 methods it'll cut down on some the the trial and error.

      Thanks!
       
    6. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      Well, things are a bit different now, I now know why things went so wrong with the swap, even tho it still came out ok, and is still going great, I think it was because I didnt own her, and that thought in the back of my mind that she could be taken away if I got into severe financial problems..... well, now I own that bitch, I get the title this week, and shes goin back into the garage for an extreme overhaul.... and now that I dont have $440/month payments on her, I can sink more $$ into doing the SAS better. Shes already a stong truck..... but soon she will be awsome!!!
       
    7. hvac man

      hvac man Elite Explorer

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      HELL YEAH :)
       
    8. cdsl227

      cdsl227 Elite Explorer

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      Since mine is temporarily held up...actually rebuilding the axle is going slow- I'm sure I'll be back for some great ideas. I'm just lazy...

      That is unless you go to coil! Cause I'm keep'in my leafs! :D
       
    9. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      Im stayin with leafs, much less to go wrong with leafs, much stronger and more reliable. only way I'd change was if I went to coil-overs. leafs flex just as good, if not better then coils.
       

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    10. Isles4evr

      Isles4evr Elite Explorer<br>ECX Member

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      I have a few quick questions for ya. Did you keep the stock waggy steering? And what type of spring did you go with? I was told that the stock waggy leaf pack with 7 leafs was strong enough for the front end. I just picked up a set of waggy 44's this weekend, and hope to have the swap done soon.

      Thanks for your help,
      Chris
       
    11. NOTAJP

      NOTAJP Moderator Emeritus Moderator Emeritus

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      Amen!:D :D :D
       
    12. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      So check this one out.... as some of you know, I had a problem with my truck being all over the damn road ever since the SAS, Ive been going over all my work, and had some other ppl point out some things as well, but noone can figure out why the truck was all over the road all the time..... well I call Maxxis (my tire sponcer) and was asking about gettin a set of the new Creepy Crawlers, while I was on the phone, I found out that the Mudzillas were discontinued due to problems like mine.... so I do have one thing to say to all that doubted me.... MY WORK WAS FINE!!!! IT WAS THE DAMN TIRES ALL THIS TIME!!!!


      And waggy leafs are a bit flat but they work great for flexxing. they were designed to sit almost flat from the factory, so your almost guaranteed to see them sit flat on your X.
       
    13. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      new t-case, bumpers, tires, steering box, etc... along with some interior stuff goin on now.... new digital cam too so Ill be sure to take alot of updated wheelin pics.
       
    14. cdsl227

      cdsl227 Elite Explorer

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      Don't forget to get closeups of the spring mounts!

      I'm getting close to that point and I'm kidnapping ideas from everybody!

      I mean you gotta try out that new camera, right?
       

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    15. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      Holy crap!

      taking it to the next level so soon after taking it to this one?

      hahaha SWEET!!!!

      Keep us posted.......and how do I get a tire sponsor? :)
       
    16. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      OK... the new t-case is in the truck.... ok, well its in the back seat.... but its closer then yesterday to being installed!!!!

      its just too damn cold out, and the heater in the garage dont do much for the cold ass garage floor....
       
    17. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      and the cold ass tools. I know how that goes
       
    18. fury

      fury Active Member

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      hey lizardtrac i was wondering what kind of steering system you are currently running beacuse i am about to swap in the same kind of axle and having a little trouble with it. also if u have any advice for my sas.
      thanks for your help
       
      Last edited: January 23, 2004
    19. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      steering was probably the biggest pain in the ass, I tried a few different ideas with a few different steering boxes, I ended up with a first gen or ranger steering box (same thing) I went to the auto parts store and got a new steering link (drag link) and had it custom bent, from there down is stock waggy. The part about the steering that the worst is mounting the box, you will have to drill and sleve holes in the frame and shorten the steering shaft (from the firewall) You will also have to have custom power steering lines made.

      gear box (used) $35
      new hydrolic lines $40
      bolts & hardware $20
      patience..... PRICELESS!!!
       
    20. fury

      fury Active Member

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      cool thanks for the reply. i think i decided to go with a hy steer setup. got me some flat top knuckles this weekend. so just deciding on a steering box right now. and i to agree that the steering will be the hardest part of the swap.
       
    21. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      swapped out the 4405 to to a 1354 manual t-case...

      if anyone need the adaptor for the 4405 front shaft let me know.
       
    22. joe_dejesus

      joe_dejesus Member

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      lizardtrac,


      nice truck!!, QUESTION: what did you use for front leafs and brakets? of the same truck you got the D44 from?


      thanks
      Joe
       
    23. Skunk

      Skunk 2/1974-4/2015 RIP Elite In Memoriam

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      stock waggy front leafs, I made all the brackets and hangers from scratch.
       
    24. joe_dejesus

      joe_dejesus Member

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      lizardtrac,

      do the waggy front leafs/diff come stock under axle or over axle?

      Reason I am asking, i rather leave axle on top of leaf , if it comes that way to match the stock explorer rear...

      I am looking for front end stength rather than more lift at the same time...
       
    25. DasFrem

      DasFrem Elite Poseur

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      The Waggy 44 comes sprung under stock, just like the Explorer rear.
       
    26. joe_dejesus

      joe_dejesus Member

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      Cool!!!

      1 less step.... both front and rear can always be done at a later time......
       

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