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SVO42's 1-ton SAS

Discussion in 'Solid Axle Swap Registry' started by SVO42, February 23, 2009.

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    1. SVO42

      SVO42 Active Member

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      I've been wanting to do this for a while, and I finally had the opportunity. I picked up my "new" axles yesterday: a HP Dana 60 front and a Ford Sterling 10.25" rear, both from an '87 F-350.

      My plans as of right now are:
      5.38 gears
      rear Detroit Locker
      ? front
      doubler transfer case: BW 1354/Dana 20
      38"+ tires
      :smoke:

      So it begins!

      [​IMG]
       
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    3. IZwack

      IZwack Moderator Emeritus

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      Your goal is to finish before me!

      And how did you get a loaded D60 into an Explorer -- cauz mine had to be forklifted into my van and I swear I'm an inch shorter after moving it from the van to the basement.
       
    4. kert0307

      kert0307 Well-Known Member

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      I was wondering the same thing. The carpet is still in tact as well.
       
    5. Dannyboy

      Dannyboy Other Make & Models Mod Elite Explorer Moderator Emeritus

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      WOW, I too have moved these axles before and that was my first thought when I saw them. You for sure would be splattered all over the place if you were in an accident with these axles flying around the rear of the truck.

      Looking forward to the build.
       
    6. Four0Sport

      Four0Sport Elite Explorer

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      i thought about hauling a motor home in the back of my explorer.. after imagining everything that could go wrong, and trying to figure out how to get it in and out, i called a frend with a pick up. haha
       
    7. SVO42

      SVO42 Active Member

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      I didn't have any other option besides using the Ex. We got them in there by having the axles on an engine hoist. The hoist wouldn't roll becuase it was all on gravel, so I left the liftgate open and backed up until the axle was inside. Once it was in the truck, we had to work them around so the liftgate would close. To do that we used a little rolling platform about 1' x 1' and a jack.

      You think a Dana 60 is heavy, try moving a Sterling! It was heavier. :eek: Here's another shot and you can see the differences in size, esp. the pumpkins:

      [​IMG]


      I really wanted to get this guy to help, but he wasn't available:


      [​IMG]


      I tried not to think about axles flying. I just kept telling myself they were too heavy to go anywhere. It helped that I actually don't have carpet--my Ex is a BASE model XL: rubber floor, vinyl seats, manual trans, manual transfer case & hubs, so cruise or tilt, no power options. When I got it it still only had the AM/FM radio. The only options it came with was the roof rack, rear wiper, and A/C.

      Proof:

      [​IMG]

      IZ: I'll try to get my swap done before you, Mr. President! :p:
       
      Last edited: February 23, 2009
    8. SVO

      SVO Moderator Emeritus/Doctor Moderator Emeritus

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      I know how heavy those axles are, I just got through putting one in my F350 dually (rear), so when I saw the pics above I just about crapped myself :eek:


      BTW your rear axle has smaller brakes than the HD70 for the dually, HEAVY, HEAVY, HEAVY!


      Heavy Metal






      Jeff - :navajo:
       
    9. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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    10. mynameisaric

      mynameisaric Well-Known Member

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      i got mine in my explorer all by myself to get them regeared, and i'm 5'11 150lbs.......

      Then again, I had them all stripped down, nothing past the inner C's, or shafts. :D

      To get them home the first time, i phoned a friend with a pickup. got them in with an engine hoist, and got them out with a makeshift gantry consisting of 2 ladders, some pipe, a chainfall, and miscellaneous lengths of chain and shackles to hold it all together.
       
    11. SVO42

      SVO42 Active Member

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      Update

      Due to some work concerns for myself and my friend who is helping me with the swap, the axles sat in the back of the Ex until this last Thursday night! I had to drive it some still, which was white-knuckled after you guys talking about nothing but my possible death due to flying axles! :p:

      They're out now at my buddy Neil's shop. I placed my first real parts order tonight. It's the front leaf springs which I ordered from BJ's Offroad, a Full Size Jeep parts store. I'm going to be doing a similar build to section525. Instead of stock height springs, I got the 4" lift ones.

      I'll be ordering gears and locker(s) within the next week or two! :D
       
    12. Four0Sport

      Four0Sport Elite Explorer

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      ive been eyeing up a stock full size jeep.. not for a swap, but just for an awesome 4x4 vehicle. keep us updated on the build.
       
    13. SVO42

      SVO42 Active Member

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      The first NEW parts arrived yesterday: 4" front lift springs for a FSJ from BJ's Offroad:

      [​IMG]

      :cool:


      I should have the gears by the end of next week. Hopefully the axles will be getting some work done the weekend after next.
       
    14. Turdle

      Turdle Moderator Masterbaker Staff Member Moderator Elite Explorer

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      So, will this be ready for Smorr? I hope that its the goal because I want to see this in person.
       

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    15. SVO42

      SVO42 Active Member

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      I hope to have it ready by Memorial Day weekend for another event! :confused: Actually, I'd like to have it ready a bit before that to do a little on- and off-road testing. I want to keep it somewhat streetable for until next winter's over. After that I hope to have a tow rig and trailer. Once I have those it will be modded even further! :biggthump
       
    16. RockRanger

      RockRanger Elite Ranger Elite Explorer

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      Are you building your own doubler?
       
    17. SVO42

      SVO42 Active Member

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      I left a message Friday at D.D. Machine about getting one. a 1354/D20 is my first choice, 1354/D300 second, and a 1354/1354 as my last option. I want a gear-driven case so I can twin-stick it. The D20 and D300 also have aftermarket lower gearsets available.

      Once I can actually talk to Duffy and see what he can do for me I'll have a better idea. He has a very good reputation and I would much rather get a doubler from him than try to reinvent the wheel.
       
    18. RockRanger

      RockRanger Elite Ranger Elite Explorer

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      I have a 50/54 combo from him in my truck. Best mod I did to it.
       
    19. Goldilocks

      Goldilocks New Member

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      Hey sexy, do you need a date for those events? I might be able to clear my calendar :D (I will wear appropriate footwear)

      [​IMG]
       
    20. SVO42

      SVO42 Active Member

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      ^
      |
      |

      My wife, everybody. She's done nothing but nag me about all of this. "Have you ordered those parts yet?" "You'd better hurry up and get those parts!" I don't know how I stand her... :rolleyes:

      :cool:

      Anyway, it's like Christmas in April waiting for me when I got home today:

      [​IMG]


      HP Dana 60 5.38 R&P and full installation kit:

      [​IMG]


      Ford 10.25" 5.38 R&P, full installation kit, and Detroit Locker:

      [​IMG]


      I also ordered a pinion yoke but it wasn't in the packages. Hopefully I'll know the deal tomorrow.

      :bounce:
       
    21. Turdle

      Turdle Moderator Masterbaker Staff Member Moderator Elite Explorer

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    22. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Wow! That's frigging awesome! Whoo Hoo!

      Yeah, how do you stand a nagging wife? LOL! Wish my ex wife nagged me about that kind of stuff, we would probably still be married!

      Are you installing everything your self?
       
    23. nssj2

      nssj2 Active Member

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      subscribing. i was thinking of doing a similar swap this summer. how much do those puppys stick out? or are you going to chop the axles? if you don't mind, about how much did you drop on the gears and bearings? definitely should turn out pretty sick though :thumbsup:
       
    24. SVO42

      SVO42 Active Member

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      I just know your basic shadetree mechanic stuff along with some good electrical and radio info. I haven't worked on axle guts before. A buddy from my 4x4 club is going to be helping me out with this stuff and he's done this type of work many times before. I'm hoping to pick up a few things myself.

      As far as the cost so far (S&H not included in prices):

      HP Dana 60 and 10.25" axles: $1,250

      leaf springs: $270 (shipping was a killer since they came from WA state)

      Dana 60 R&P + full installation set: $300
      Ford 10.25" R&P + full installation set: $300
      Detroit Locker for the 10.25": $600
      1410 U-joint pinion yoke for the 10.25": $210

      The axle parts I got from Complete Offroad (http://www.completeoffroad.com). They had better deals than anyone else I could find. S&H was only $11. I placed the order late last Thursday and it got to me the following Tuesday. Pretty good! Of course, they're in Iowa and I'm in Missouri! Still waiting to hear about why I don't have the pinion yoke yet.

      I'm leaving the axles full width. I haven't measured them myself yet, but will post once I do. According to the Dana 60 Bible on Pirate, the Dana 60 I have is 69.25" WMS-WMS, about 10-11" wider than my current Dana 35 TTB. I'm sure the Sterling's about the same. I don't want to cut them down for two reasons:

      1. Easier to get replacement axle shafts if needed. I know I might be able to but the long side of the 60 to some other shorter, stock length but I don't want to mess with it.
      2. Wider = more stable.

      I'll try to get some measurements this weekend. I'm getting excited!
       
    25. Pollarican

      Pollarican Active Member

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      Lookin' good so far! I'll definitely be keeping an eye on this.
       
    26. Setinu

      Setinu Member

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      You going to lock the front? what size tires you going to run?
       

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