The #1 Ford Explorer enthusiast resource for over 25 years!
Performance upgrades, maintenance, modifications and problem solving. Covering the Explorer, ST, Ecoboost, Lincoln Aviator, Sport Trac, Mercury Mountaineer, Mazda Navajo, Ford Ranger, Mazda Pickups, and the Aerostar.
If you have completed a solid axle swap on your Explorer and would like to share the results with others this is the place to do it:D This isn't the place to talk about a work in progress, rather a place for the FINAL results, specs, instructions etc
So you want to do a SAS on your Explorer/Ranger/BII? Dont really know were to start? To much info to sort through?
We can help. :) This thread is the be all- end all of Explorer, Ranger, and BII solid axle swap tech info.
Solid front axle data thread by FROADER
Bolt in D44 swap The easiest SAS imaginable, practically bolt in by Dannyboy
So you want to do a V8 swap in your Explorer, Ranger, or Bronco II? Well here is a compilation of V8 swap threads-
old general tech thread by Gofast
5 liter and 4R70W into a 1st gen. by seth2472006
5 liter and 4R70W into an 03 Ranger by rwenzing
5 liter and T5 into a 1st gen. by Chief34
4 liter M5OD to A4LD to 5 liter 4R70W by 410 Fortune
5.0L/4R70W 2WD into a 1st Gen (WITH a 2nd Gen Dash Swap) Spdrce
As some of you know, I am working on building a parts list for a shortened Dana 44, long radius arm with coil overs SAS. 5:13 gears to match my rear axle and an ARB, maybe an electric locker. I have a pretty good list so far. At the same time, I am going to swap out the rear drum brakes for discs off of a 99 Explorer.
Please note: The plan is to keep this project as simple as possible with mostly off the shelf parts. I am not a fabricator, just a decent welder with a what I would consider the minimum required tools (chop saw, cut off wheels, air tools, welder, etc.), who likes doing his own work. Your opinions are welcome, but what I really need is technical advice. I have been thinking about this for several years and now...
I haven't posted much here since I sold my 1993 Mazda Navajo around 2010 or 2011. It was 10 years in the making and finally to a solid, reliable state. I had some other priorities and decided to sell it and get something more versatile. I will include some pictures below of its developing states and final state when I sold it below. In the end, it had 37" MTRs, Arb front, detroit rear, 4.56 gears, D and D doubler and I built all the armor and the Dana 44 front Solid Axle Swap.
James duff 3.5" VR coil lift, 235" defender tires and a home made heavy ugly bumper (around 2000 when I bought it) :
2001 with 33x10.50s and James duff 4.5" lift with extended radius arms, manual hubs and new auto tranny:
Here it is just after the SAS...
Okay here we go 09/13/05
In march of 05 I rolled my new to me 96 5.0L AWD 86K miles, just after driving it back to CO from OR and putting $1000 into it. You see I bought this truck from my brother with 86K miles on the clock, it would not pass emissions for him and he drove it into the ground. This was the same explorer he bought new when I got the BII from him for $500 12 something years ago.
Well I payed him $500 for the green Explorer and $1000 later (shocks, tune up, 02 sensors, etc) it was in primo condition. Then I rolled it in an ice storm...
RIP 96 EB:
So in April my buddy Brett found this great deal here in town for a 96 XLT 5.0L AWD, $900 is what I paid, it has front end damage and air bags deployed, picked it up...
LD50 Full-size axle thread `93 Ex SAS
Hey fellow Explorer enthusiasts!
Well I never thought I`d do it, but it`s time.
I originally thought I would go to a smaller rig one day but I`m going to beef up the Explorer instead. Since I already have a huge thread on my previous work I decided to start fresh.
If you would like to see my previous mods, you can navigate from my signature link, or click here:
My plans are to install a D44 and 9-inch into the station wagon and run 35 inch tires. Hopefully she`ll still get in the garage, but if it don`t then oh well. During this I also have some body work to do.
Right now I have the rear end out, I took off...
Alright so some of you know Ive been painting my truck the last week, and I was going to wait to show it off at T-haven...But I know you all can't wait and I'm to proud of my hard work:D
So here are some pictures I took with my cell phone.
Still have more to do, need to remount the front bumper, wetsand the whole truck and put on the JP logos when they get here..
The entire paint job was done using a $10 air sprayer from Harbor Freight and Rustoleum paint. The green I actually custom made, as no color was available like that.;)
Here is the original...in case you forgot:p:
Some of you may know, and some may have suspected, but I'm starting a new project and it starts with a truck you all will recognize.
I picked up R.J.'s Navajo today. She is a little tired and was facing being parted out, but now will start a new chapter, a very different chapter. I give you Plan B.
So let's start off as to why "Plan B"? Well, it has multiple meanings.
It starts off as I really wanted a early Bronco. I first learned to drive on Zukmans '71 Bronco he had years ago. But myself owning a early Bronco was not going to happen. There just way to ridiculous priced these days.:eek: So this is My Plan B.
JP is not going anywhere, I really just wanted to to do another build and JP is...well, JP!. It works, but it...
I have a thread up in modified 95-01 Explorers, but since mine is mainly off-road I figured it would be more suitable to have a thread in here.
What I am working with
97 2wd Explorer 4 door with 5.0L V-8
Front suspension: 14" Wheel travel
Modified LCA to accept a 1" uniball as the outer pivot then boxed in accordingly. Custom UCA with 7/8" heim as outter pivot and 3/4" heim on frame pivots. Fabtech lift spindle tapped out for the heim and drilled knuckle for a 7/8" on the outter tie rod as well. Fox twin tube bypass shocks as well as a 2.0 body air shock per side assist the stock torsions with spring rate. Fox hydraulic bump stop off of the UCA
Rear suspension: 18" wheel travel
62" race leaf springs by Deaver with custom 12" long...
So you think you want to put a 302 in your 91 to 94 Four Wheel Drive Explorer? My advice is plan, then plan some more. Ask questions, then plan, and finally ask more questions then plan. You get the point. There are several sources for doing this swap with Rangers. Most of this info is usable on the Explorers. However, some options do change the way things fit. My ABS motor on the 94 XLT is making it tough to mount a radiator. Also, Size does matter! 302’s are the easiest fit. There is not much room in the older Explorers, so anything bigger than the 302 ( Size wise, not Cubic inch wise ) is hard to squeeze in there. Yes 427’s can be made to work, but why spend all the extra money redesigning the frame? Doing this conversion...
Got a '99 ford explorer 5.0 V8 AWD looked everywhere online for a lift kit for it all i can find is people saying to just add a leaf. Does anybody know a lift kit? Trying to get 3-6 inches wanting to fit 36 tires on it thanks
I guess this is what happens when you take someone like me, add someone like Kevin (DWD), and throw in some beer!
Here's the plan. This weekend I'm looking at buying a '79 F250 longbed. It has a 300 straight 6, leaf sprung dana44 front, dana 60 rear. Basically, I'm going to put my Explorer body on the F250 frame.
First things first. I need to rebuild the 6banger, trans and axles. Then, I cut some of the frame out of the F250, bring the dana60 forward a bit. Fab up some body mounts, get creative with the engine compartment and steering linkage coming out of the Explorer firewall. Then I spend 200 or so manhours rewiring, fabbing fuel and brake lines. Then I slap on some new tires (38s?) with 8lug rims and bingo....I go...
Body mount replacement and custom Heavy duty 3/4" body lift.
Several of my body mounts had deteriorated such that the lower flanged washer and rubber mount were falling off. In the picture below I have loosened the bolt but not removed it completely.
I had ordered the DayStar Body mount (KF04009) replacement kit to replace all mounts. Unfortunately the kit only includes the Poly Bushings and no hardware. As such I had purchased the following additional hardware.
Qty - Grade 8 Bolts
2 @ 1/2" x 4.5" (Mount #1)
6 @ 1/2" x 5â€ (Mounts #2 and #4)
2 @ 1/2" x 7â€ (Mount #5)
10 @ 1/2" Grade 8 washers and nuts.
30 @ 1/2" ID x 3" OD x 1/4" thick (dock washers)
The process is similar to that of a body lift but...
I picked up my transfer case last night.
Two t cases were included in the deal, one is strictly for parts.
The t case I will be using in my 96 5.0L AWD explorer is a 2001 F-150 BW 4406 manual shift :) this makes me very happy. I will no longer have full time AWD, instead I will have 2wd, 4hi and 4 low, increased RWHP, better MPG, and less tire wear. Also a more capable truck off road for light wheeling (getting to the fishing spot, colorado winters, etc)
I have ALOT of research to do before I get started collecting more parts and modifying the t case so it can be installed...I am just beggining this conversion.
Once I get a better picture of everything that is needed I can post more.
I know I need to get the manual shifter...
Goal is to convert the D35 to 6 lug while increasing strength and durability.
Please save your breath about why I should just save all the time time and money and just do a SAS because it’s better in every way. I’m a nerd and TTB is one reason I love old midsize Ford Junk.
Subject is currently 200% stock 93 X
Build goal - Budget minded daily driver with good road manners, decent flex, max traction (lots of snow) Family friendly trail rig for hunting camping and dicking off.
I’m aiming for comfy suspension and will retain small tires for now so I can still hit highway speeds with the stock gearing. Will probably go to a max of 33’s if I get the hybrid gear swap done in the trans.
After looking at current wheel tire...
I am consolidating my build thread and the sas build into one thread so below is a link to my original build thread in case anyone has too much time on their hands and wants to see how this whole ordeal started.
notajeep_wv build thread
the next step.. SAS parts update 2/18
Its time for a SAS, time to take making Jeeps look bad to the next level lol
Lets keeps track of how much this is costing me so I can look back at it later and think of all the other things I could have done with the money.
what ended up on the truck..
74 EB D44 with track bar, steering, 2 sets of RAs - $200
F150 knuckles, spindles, hubs, rotors, calipers - $35
MileMarker premium hubs - $80
4.89 G2 gear set - $175
4.88 G2 gear set - $200
D44 install kit - $80...
Got it done yesterday, few questions please:
- How much will 4.10's and TM Headers improve my MPG? I am currently running 3.73's.
- I would like to run some wheel spacers, but I won't if it is going to add any additional stress to the truck. Thoughts on this? I am getting some rubbing in the front and I think if my front tires stuck out a bit more that it would clear completely.