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Solid Axle Swap Registry

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
Solid Axle Swap Registry Index The list views better if you select desktop view when using a mobile device. List By User List By Date List By Vehicle/Generation List By Axle Type List By Suspension Type
My solid axle swap went through two phases of construction. The first utilized Trailmaster 4" coil springs and Rancho 9000 shocks. The setup was a 5 link, that is 4 links plus a panhard bar. The coil spring was allowed to fall way from it's upper mount and was kept in line by a piece of tubular steel which also served as a bump stop. The axle is a Dana 44 High Pinion design from a '79 Bronco. The axle was shortened for this application. I do not have the measurements. All of the fabrication work was done by FST in Phoenix Here are photos from Phase 1: Main drawback to this design was the noise and sloppiness that occured when the coil spring fell away from the top mount. Everyone I wheeled with had to get used to the...
So I started collecting parts for my sas kinda half heartedly knowing I wanted to do it and it just kinda happened one day. I meant to start this thread before I started with pictures of all the parts and the process of me doing it. but like I said I just kinda started and forgot. So we are dropping in about 75% threw doing it. So here is how it sits now. I would guess about a 6" lift is where we ended up. This is the beginingish I just got most of the ifs in the front cut out and the d30 sat close to where I wanted it I'm using soa porches from Barnes 4wd and out riggers and there shackle mounts so I got the thing as centered as I could. Here's a pick of the outrigger and leaf hanger tacked in. And that's pretty much all the pic I...
A little planning and 4 months later, my Sport Trac finally has a solid axle in the front. Current Look: Front Axle - Low Pinion Dana 44 from a 1988 Grand Wagoneer - 6x5.5 bolt pattern - 4.88 gears (still open diff for now) - Superwinch manual hubs - Disc brakes - Custom spindles tapped for hi-steer - Custom 1.5"x.25" wall DOM drag link and tie rod - Stock Grand Wagoneer 7leaf pack flipped to SOA - Bilstein 5100 shocks (originally for Jeep JK with 6" lift) - Ford Super Duty steering box (pre-drilled for hydro-assist in the future) - Drop pitman arm for Super Duty with 4" lift - Front stainless brake lines for stock Jeep TJ - Custom sway bar end links - New Moog ball joints and bushings - Grand Wagoneer track bar mounted to frame rail
I've been done with my SAS for a little over a year and could'nt be more happy with the results. Here is a condenced list of mods. HP d44 OX locker 5.38 gears early bronco coils from Wild Horses 12" stroke Fox Shocks DOM tie rod and drag link 3 link with johnny joints home made bead locks d60 rear Detroit locker 5.38 gears mix of x and bronco leafs 11" stroke Fox Shocks
Well I've been a member on here for a few years but have never posted. So for my first post I decided I would add my '95 to this SAS thread because I've done a couple of thing different than a lot of the others I've seen on here. First, let me just say that I'm just an amateur and did all the fab work myself so go easy on me if there is something that you think should be changed. Second, everything has worked well. Besides already doing numerous runs also I've jumped the truck a few times now out at TDS and Lucernce Valley and everything has held up nicely. So here it is. I used a high pinion D30 out of an '88 Cherokee but used leaf springs to keep it simple and low cost. For the leaf springs I used the main leaf from a front...
So I haven't officially made a thread on my lifted explorer build. It would have been easier to track from the beggining but I just didn't get around to posting. Iv had this 94 explorer since late 2013 when I picked it up for $700 bone stock. I used to have an 85 bronco 2 that I had chopped the top on and loved how well it wheeled and performed but it wasn't big enough and had tons of issues. So the explorer fit me much better. It's a 5 speed with when I got it 228,000 miles. Now it has around 236,000 miles. Has a light lifter knock when the oil is dirty but runs really darn good tho. I started with some TTB lift at a 3" and 33s. I had found a long arm kit in the junkyard on a bronco 2 and used that lift first. I ended up getting some...
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!
will i guess it time i did one of theese :) specs Frunt HP Dana44 out of 79 bronco welded diff...$500 (frunt and rear no gears) 5.5: cage springs for F-150...................$260 14" travl shocks..................................$50 wild horses extended radius arms............$455 used 4.88 gears off ebay.......................$50 i think reabuild kit..........................................$112.07 Warn premium hubs off ebay....................$80 Gear instal...........................................$300 Rear Ford big bearing 9" 31 spline open diff motive 4.88 gears..............................$180 re-build kit........................................$22 instal...............................................case of beer :chug...
Mine is done. Build specs: Garage kept 97' v8 AWD 115,000 miles bought from og owner. Early bronco Dana 20 transfer case High pinion full width d44 with fms 5:13 gears,Detroit locker,superior shafts,Yukon super joints,t bird calipers,warn hubs,crane diff cover and relocated wedges. 9" rear from 79' bronco,,full spool,5:13 gears,31 spline shafts, ruff stuff anti wrap spring perches and plates.drum brakes ..for now 79' bronco steering box,frame fully plated and sleeved. Ruff stuff 7/8" heims steering links. 37" pro comp ABS pump delete. 1310 cv drive shafts from tom woods Duff arms,duff 2.5" coils,early bronco coil buckets,f250 Shock mounts in front stock location rear shocks B&m trans cooler with fan B.C. broncos trac bar,brake...
98 Sport D-44 SAS Complete!!! I wanted to wait till the truck was done b4 posting here, but here I am, the truck is done.... FINALLY. The gears and locker are in, and the new driveshaft is in, and it works great, I had it out on the highway and it seems to get a better ride at higher speeds..... Good thing.... Specs: D44 Front axle from a 84 Grand Waggy wide-trac 4:10 Gear ratio Locked Warn Manual hubs Leaf spring suspension Rancho 5000 shocks all around 94 X steering box Tom Woods custom front driveshaft Woodring driveshafts custom rear driveshaft rear SOA and 3" blocks Modified Tranny Crossmember (to allow driveshaft to fit) all the rest of the SAS is custom fabricated
Well since I don't have the time/tools/skills to build my own, but I do have the money, this isn't going to be a build log, just show the final product since I don't have much for "during" pics. Dana 30, trussed and gussetted. 4.56 gears, Eaton Truetrac (front and rear), SOA with Chevy 1500 63" leafs, 1354 manual transfer case, F-150 steering box.
Hi there. Last year I bought this $600 beauty. This November i turned it into this beast. Last spring i did the BW4406 transfer case swap to be done with the AWD poo. Then i spent the summer collecting parts, narrowing the front axle and getting the gears set up. The list. Factory v8 212,000 miles on the clock. '78 bronco HP dana 44 narrowed 6" completely rebuilt Chromoly early bronco shaft's Detroit locker front 4.56 gears Custom long radius arms Wild Horses 3.5" coil springs Rancho rs 9000's F/R Thunderbird calipers Gen 1 explorer front shaft modified. Inverted chevy tie rod ends, 1 1/2" tie rods Bronco2 steering gear rebuilt and tapped for ram assist BW4406 transfer case Original 8.8 completely rebuilt during SOA Welded center...
2002 Explorer Sport Trac Engine: Stock 4.0 Taylor 8.8 MM Plug wires Screamin Demon Coil XCAL2 Tuned Zabtek Cold Air intake Random Tech "Y" pipe with custom FLowmaster exhaust. A few cats have been removed. Transmission: 5R55E freshly rebuilt 1354 Borg Warner Electric Shift Modified Superlift front driveshaft Stock rear driveshaft Front Axle: 89 Jeep Grand Wagoneer Dana 44 low pinion ARB Air Locker 4:56 Ring & Pinion Superior Chromo Axles CTM U-joints Steel braided 28” brakelines Warn manual locking hubs Parts Mike Highsteer arms with 1" spacers Parts Mime highsterr knuckles 5/5.5 conversion kit Rear Axle: Explorer 8.8 31 spline PowerTrax Locker 4:56 Ring & Pinion SOA conversion Wheel...
Hi this is my first post here and I am getting close to finishing my sas swap to i though i would add my build. In the front it is a full width 44 with 456 yukons gears ox locker 7 deg bushings duffs long arms deaver springs reid racing knuckles
hp 44 ford 9 inch front end moved forward 3 inches 5.38 gears,wild horses coils and balistic heim joints.:) 1 ton tie rod ends 1 1/2 dom tubing for the steering
Hey all. this is my x that i recently about got finished up. Took 2 months working on it every other sat. I still waiting for my sway bar endlinks, hi steer arm, and tre,s to come in to re do steering. But i will include pics as well as info. Front end 78 F250 HPd44 stock shafts for now 4.88 liberty gears tru trak posi unit mile marker hubs ranger steering box 1.5 OD .250 wall dom 79 outters reid racing hi steer knuckle 4 stud OEM 5 leaf waggy springs rustys offroad break lines rustys offroad shackles blue torch fab weld together shock hoops bilstien 5125 14" travle shocks Rear 93 8.8 f150 rear eaton carbon fiber posi unit liberty 4.88 youkon chromoloy shafts stock explorer rear disc re drilled rotors some...
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