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DUDER 1's 94xlt SAS

Discussion in 'Modified 1991-1994 Explorers' started by DUDER 1, March 26, 2015.

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    1. DUDER 1

      DUDER 1 Elite Explorer

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      So for some updates, We had to figure out brake lines because I remove the factory hardlines. I wanted to run the brake lines like the factory bronco the single center down to the hardlines to the soft outers. We also had to modify the stock brake line bracket by extending it up to clear the Cage radius arms. we also had to grind out the flat spot in the bracket because the new lines were a little larger than the factory brake lines. My good friend at B&M Machine in Lake Isabella California help me get the front and back on the Ex over the last week. I decided to go with brake lines from Crown Performance in California. If you need lines from them speak with Jeff he is very helpful. The hardlines came from Carquest and are easily bent by hand. I decided to keep the factory break proportioner in the truck for now so we made a two into one adapter from the factory proportioner.
       
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    3. DUDER 1

      DUDER 1 Elite Explorer

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    4. DUDER 1

      DUDER 1 Elite Explorer

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      The next photos are just progression of the axle being put back in and the install of the F-250 shock towers with Bilstein14 inch 5125 series shocks. We also installed new spindles with the wild horses extreme bushings and a new Warn premium locking hub set. Everything was replaced from seals to u joints and Heim joints.
       
      Last edited: April 18, 2017
    5. DUDER 1

      DUDER 1 Elite Explorer

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    7. DUDER 1

      DUDER 1 Elite Explorer

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    8. DUDER 1

      DUDER 1 Elite Explorer

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      The next photos are of how we set the front brake lines up. If anyone has questions please ask I'm sure I'm leaving a lot out.

      [​IMG]

      [​IMG]

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      [​IMG]
       
    9. DUDER 1

      DUDER 1 Elite Explorer

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      [​IMG]

      [​IMG]

      [​IMG]
       
      Last edited: April 18, 2017
    10. DUDER 1

      DUDER 1 Elite Explorer

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      We finished putting the explorer back together Saturday. We took the family out to a local trail in Keysville called tombstone.
       
    11. DUDER 1

      DUDER 1 Elite Explorer

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    12. DUDER 1

      DUDER 1 Elite Explorer

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    13. DUDER 1

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    14. exploregon94

      exploregon94 New Member

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      very clean build man. looks like she works great on the trail! :thumbsup: I got one question. when I had started my build with a D44, I was told I couldnt use the Ford Knuckles as flat tops for high steer arms. Did you have your passenger side milled and drilled? I went with chevy flat top knuckles instead.
       
    15. WormsExplorer

      WormsExplorer Elite Explorer

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      Very nice build sir. How is it holding up so far? Like how you did the brake lines.
       
    16. DUDER 1

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      I am using the factory Ford knuckles. The passenger side one was drilled and tapped.
       
    17. DUDER 1

      DUDER 1 Elite Explorer

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      Thank you the brake lines came out nice. BKennedy helped me out with ideas on the brake lines. The truck is holding up good. The power steering puked out all of its fluid the first run so it's time to upgrade. I was given a Saginaw style pump so that's what I'm going to put in it.
       
    18. james t

      james t moderation Staff Member Moderator Elite Explorer

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      Question-

      How close are your radius arm mounts to the trans crossmember? Is your front axle pushed forward any or is it mostly in the stock location?

      Im seriously considering ditching my home-made arms and getting those to get my turning radius back... but my front is 3" forward and i want to keep it that way.
       
    19. DUDER 1

      DUDER 1 Elite Explorer

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      Good morning sir,

      I am not sure if my axle is pushed forward or not because the work was done prior to us getting the explorer. It looks like the axle may be pushed forward a bit. The attached picture shows the trans crossmember and my radius arm mount. You can see that there is still room to move forward a bit. I will get better photos when I get a chance. Thanks for looking.

      [​IMG]
       
    20. james t

      james t moderation Staff Member Moderator Elite Explorer

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      Thanks... That helps!
       
    21. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

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      That flexes nice. Did you notice how much more stable it is on off-camber stuff?

      I noticed my power steering pump really labored because I had the steering stops set wrong. They need to be set the same as the limits of the box, or as near as you can get them. If they are set to stop the steering before the limits of the box, and the stops make contact, the suspension on these long travel axles will flex and put a ton of strain on the power steering. With the Explorer parked on flat ground and the engine running, turn the wheel all the way to one side. If it hits the stops, and the hood starts dipping on the side of the outward turned wheel, your stops are too long. I think that's why my pump blew shortly after I finished my SAS.

      I have the same arms and my axle is forward 1.5", but I have a different transmission/transfer case and cross member. I measured and added another 1.5". If the radius arms were 3" forward, the front edge of the Duff RA bracket would be 16" back from the center of the first body mount bolt on the driver side. I think that would still clear the stock cross member going by the old rivet holes. 3" is a lot; my 35" tires clear the firewall, but contact the front and inside of the metal inner fenders. I also had to trim the front fender well edge to clear the tires at full stuff.
       
    22. DUDER 1

      DUDER 1 Elite Explorer

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      BKennedy,

      I think with the rear leaf mod and the bilstein shocks up front made it more stable. I only had the chance to wheel it that one day so I would have to test it more but the truck feels a lot better than it did when I bought it. The truck also had 2° radius arm bushings installed when I bought it. I replaced them with 4° bushings and that seemed to help the truck track better on the street. I really appreciate all your help and time that you take to answer my questions.
       
    23. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

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    24. DUDER 1

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      Last edited: May 12, 2017
    25. DUDER 1

      DUDER 1 Elite Explorer

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      We made A family trip to Crown King to get lunch, ice cream, and fudge. I needed to knock the dust off this old girl. We have only put about 100 miles on her in the last two years lol.

      IMG_4457.JPG
       
    26. DUDER 1

      DUDER 1 Elite Explorer

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      IMG_4453.JPG IMG_4456.JPG IMG_4451.JPG
       
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