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Mn Mountaineer V8 SAS

Discussion in 'Modified 1995-2001 Explorers' started by johnny499, July 28, 2014.

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    1. rabbit91

      rabbit91 Elite Explorer

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      If I did a SAS again I would do coil over instead of coils and shocks. The cost is not a whole lot more and in both cases need to be fine tuned after being put together.
       
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    3. bronchole

      bronchole Driveway flexing! Elite Explorer

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      I am considering changing over to coil-overs rather than spending the money a good pair of shocks for my existing SAS. By the time you spend over $400 on a good pair of shocks, you are over half way to a pair of coil-overs... I hope ;)

      Funny thing, I was looking at this thread earlier and my wife say your front bumper. She said she liked it allot and wondered when I was going to do one similar. I know, I got a winner!
       
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    4. johnny499

      johnny499 Elite Explorer

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      I agree, I was trying to get by on the cheap. I already had the adjustable shocks and it would be fine if my educated guess on the spring pocket height would have been lower.

      She clearly is a keeper!!
       
    5. johnny499

      johnny499 Elite Explorer

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      I started to make brackets for the ram assist but got interrupted and haven't got back to it. I also haven't made any decisions on the front spring situation. I have thought about cutting 2 inches out of the spring towers as a quick and cheap option also. On a side note it is so nice to be able to lock in the hub's and switch in and out of 4wd in the snow without the front locker getting all crazy and ratcheting away.
       
    6. johnny499

      johnny499 Elite Explorer

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      This weekend i did a full lube and oil change which motivated me to look at the ram assist again. I finished making the tabs to mount the ram and tacked them in place. I came up with a possible plan for the tie rod clamp. I tacked a bolt to the clamp and cycled the steering to check clearances. It fit with no contact issues so i welded the tabs onto the axle housing. i think i am going to add a gusset just because. Now i need to decide which way i want to go with the clamp. I can weld a bolt to it or i can weld a boss to it then drill and tap. the fun part is they are 5/8" fine thread bolts, i don't know if i have access to that size tap.
       
    7. johnny499

      johnny499 Elite Explorer

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      I thought i would get the pictures of the ram assist caught up here.
      501.jpg
      The axle tab's just out of the shear.
      502.jpg
      The tabs supplied with the cylinder kit above mine freshly sanded and ready for the mounting hole.
      503.jpg
      I tacked the brackets to the upper panhard bar mount.
      504.jpg
      Then i tacked one of the bolts to the tie rod clamp and mounted up the cylinder.
      505.jpg
      I cycled the steering slowly checking clearance along the way. It will be tight at the pitman arm when at full left lock and full compression. I was concerned about the the tie rod clamp clearing the diff cover but that wasn't an issue.
      506.jpg
      Everything clears but it will be interesting getting the hoses figured out.

      I still need to make a final decision on the tube clamp attachment point. If I can find a 5/8" fine thread tap i will make a boss to weld to the clamp and thread all the way into the clamp for that little extra engagement.
       
      Last edited by a moderator: February 4, 2018
    8. johnny499

      johnny499 Elite Explorer

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      I'm going to try to hit the off road park at the iron range with my dad on Saturday. It will be the first time there so pretty excited. It's a good 3 hour drive to get there.
       
    9. johnny499

      johnny499 Elite Explorer

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      My dad and i made the trip Saturday to the Iron Range Off Road park. it was 3 hours each way and we ran the trails for about six hours. The weather was perfect and the park is great.
      510.jpg
      We were pretty cautious most of the day, I'm still getting use to what it can handle. It flex's really well.
      511.jpg
      We did do a bunch of the black diamond trails but shied away from the really intense spot's for now. I would have tried more if we had gone up on a trailer.
      512.jpg
      I made it to the exit of tailpipe alley when i miss judged the drop behind a large rock on the drivers side and kind of mangled the running board. Then I backed back up the rock and jockeyed to the right and slid down the side of it.
      513.jpg
      We went over a lot of large rocks with out dragging or touching any of them till that.
      514.jpg
      The views were incredible...
      I will definitely be going back again..
      Now I need to make sliders :cool: and finish the ram assist.......
       
      Last edited by a moderator: February 4, 2018
    10. johnny499

      johnny499 Elite Explorer

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      521.jpg
      So after bending and knocking the running board loose on the trail i decided to make the rock sliders that i have had the material for since i started the project. You can see that 246,000 miles in Minnesota have not been kind to the rockers.
      522.jpg
      I started with 1/8" wall 2" by 4" tubing cut to length with tapered ends.
      523.jpg
      Then i sheared 1/8" thick by 3 1/2" flat stock to length.
      524.jpg
      Punched a series of 3/4" holes in them and started welding them to the bottom of the tubes for better impact resistance.
      525.jpg
      With that started i clamped the tubes together and stitch welded them together to minimize bowing while i weld on the plates. I welded a section at a time then flipped the tubes and did the opposite side to keep the warping in check.
       
      Last edited by a moderator: February 4, 2018
    11. johnny499

      johnny499 Elite Explorer

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      [​IMG]
      I got both of the tubes skinned.
      [​IMG]
      Then i cut them apart. They did bow a little, actually about a quarter inch in the center over the six feet.
      [​IMG]
      I ground the welds and capped the ends so the majority of the heating would be done and i could move onto straightening them.
      [​IMG]
      I did a quick research on heat straightening, clamped the tubes together loosely.
      [​IMG]
      Fired up the torch and heated the tubes in five spots each starting from the center and worked my way out.
      [​IMG]
      This worked quite well but i ultimately wound up doing it one more time centering the next heat points between the previous ones.
      [​IMG]
      That did the trick it pulled them just a little bit past straight. close enough for me i was quite please with the result. i haven't used that method to straighten anything before. It took time but worked awesome.
       
      Last edited: November 28, 2017
    12. johnny499

      johnny499 Elite Explorer

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      2001.jpg
      With those done i mocked them under the mountaineer, decided how i wanted to do the tubes and threw some measurements in the computer. The software has really made getting things bent right the first time so much easier.
      I used the same 2" .120 wall tubing that i used for the bumpers.
      2002.jpg
      I tacked the tubes on so i can mock them up under it again and decide how many struts i want to do and if i want to make step plates.
      2003.jpg
      Once i get all of the kinks worked out it's going to be time for a new body!!!!!!!
      2004.jpg
      It looks like i won't be gaining or loosing any ground clearance, just going to have better protection and a solid step...
       
      Last edited by a moderator: February 5, 2018
    13. WormsExplorer

      WormsExplorer Elite Explorer

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      Looking awesome so far. Can't wait to see the end results
       
    14. SWIGIN

      SWIGIN Active Member

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      Yeah looks great!

      I cant wit to see how you attach those to the frame.
       
    15. johnny499

      johnny499 Elite Explorer

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      Thanks, they should fit the theme of the rig and finish it out as far as protection goes.

      I plan to weld 1/4" plate to the frame and use the 2" round tube to go from those plates to the slider tubes. I would try bolting them on but i have zero desire to drop the fuel tank and work around all of the lines on the drivers side. I also think they will be stronger welded on. The fun part will be working around the parking brake cable.
       
    16. johnny499

      johnny499 Elite Explorer

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      Thank you Photobucket for being so craptastic!!!!!!!!!!!!!!!!!
      Now i need to find another hosting service.
      Oh well i did manage to get the drivers side slider mocked up and then cut the mounting plates loose from the frame so i can add gussets, finish weld and paint all but the perimeter of the mounting plates.
       
    17. SWIGIN

      SWIGIN Active Member

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      That sucks bout the pics.

      I was trying to look back through your thread to find out what you did with your ABS but it's too hard without the pics.

      I was wondering if removing the ABS affected the speedometer at all since I've read that they share the same tone ring in the rear on our 98s?
       
    18. johnny499

      johnny499 Elite Explorer

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      For now i left the ABS unit under the hood but plumbed the brake lines around it. I tried to wire around it with the speedometer correction module and it worked for the speedometer but the cruise wouldn't work. I plan to remove the pump portion and just leave the electronics module.
       
    19. johnny499

      johnny499 Elite Explorer

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      The sliders are done but I have not decided how i want to host pictures going forward. The "Photosuckit" drama has hurt the worst on the 79 page thread i have on the restomod of my cummins powered f350......
       
    20. SWIGIN

      SWIGIN Active Member

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    21. rabbit91

      rabbit91 Elite Explorer

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      stupid photobucket!!
       
    22. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      try using www.cubeupload.com
      uploading is free and works good.

      would be great to see the photos. (i know its a pain, but I hope you repost them.) :)
       
    23. 99SportX

      99SportX Elite Explorer

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      Dang, I just checked this thread again since quite a while ago. I see that you finally made it up to the Iron Range but I can't see the pics due to the photobucket fiasco. :(
       
    24. johnny499

      johnny499 Elite Explorer

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      I had a blast up there and plan to go back now that the sliders are done. I will get the photos re-posted from another source one of these days. At the moment my time has been taken up by preparing for a varmint hunting trip to thunder basin national grasslands in Wyoming over Labor Day weekend. It sounds like i may have to do some trail riding to get to the hunting spot's. Darn the luck. :chug:

      Road trip:burnout:
       
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    25. johnny499

      johnny499 Elite Explorer

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      Well the trip didn't go as planned, we made it just past Wall, S.D. when the noise we thought was the heat shield for the muffler turned into a whirring sound and then shortly after a growling sound and a nasty vibration in the transfer case shifter. We pulled into the next tiny town that had a four room motel at 10 p.m. i checked everything i could but saw nothing obvious external. i got up early the next morning and with everything cooled down I checked the fluid level which was a little over full. The fluid was black and very thin. I check the wheel bearing which i packed the day we left and all seemed fine there so i called my dad to bring the one ton and car trailer to get us. He showed up around midnight after prepping his trailer and gather supplies. we loaded my little trailer in the back of the truck and then put the Mountaineer on the car trailer. We talked him into continuing the 150 miles to our intended destination. we took the car trailer off and used his one ton two wheel drive dually to do the trail driving which limited our access to the good shooting spots but we worked with it and had fun with it.
      [​IMG]
      This was us when we left MN.
      [​IMG]
      [​IMG]
      This was us in WY.
      [​IMG]
       
      Last edited: November 20, 2017
    26. johnny499

      johnny499 Elite Explorer

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      We made it back Monday. Tuesday i found a replacement BW4406 at the junk yard. Wednesday night I put it on the hoist and drained the fluid. I reached in through the drain hole and pulled large chunks of metal out of it so my diagnoses was confirmed. I got the old one pulled out that night and the new one in the next night. Friday afternoon i took it on a 150 mile drive up north for a funeral. I just realized i haven't tried the four wheel drive functionality yet.....
       

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