Solid Axle Swap Registry

Finilly got it finished, im running 5.13s, 14" airshocks, and Aussie lockers. It is sitting to tall in the front right now i need to drop about 50psi. Any questions just ask. And a little poser shot :D

so after a long time, money burning a hole in my pocket, and the devil on my shoulder..I went ahead and cut up my explorer. I started out with 2 dana 60's..one was a full float with brackets, 4.10's and stupid drum brakes. I went ahead and took the ring and pinion out of that and set the rest aside for a rainy day. Then I got my dana 60 housing, which is a semi float 5x5.5 pattern axle with no brackets, carrier, or gears. i rebuilt the whole thing and stuffed in the gears. after that part was all finished, I went out and got a set of ballistic fab GM caliper brackets and calipers, also I got the old axle out and thrown aside Then the new axle was all ready to be put in..so I switched the springs around in the rear to give me a little...

I have been working on this for awhile now...Big Red is almost done but is driveable. I made a website for it awhile ago, so i'm just going to post the link for that. Feel free to shoot me any questions or anything i could have done better! http://bigredexplorersas.webs.com/ got some short videos http://www.youtube.com/watch?v=gvW_QuExpIU more to come

Got Flex? :D Dead Link Removed Setup consists of: Front: Rubicon Express Long Arms for TJ's Custom D44 front axle: -High Pinion -4.88's -Elec-trac -TJ width (~2" wider than stock explorer) -TJ brackets -Chevy outers; 11" disk brakes, Warn premium hubs, 5x5.5 bolt pattern Sway-a-way RaceRunner coil-overs: -2" reservoir, 14" travel shock -dual rate Eibach springs; 250, 300 1st gen. steering gear box -hybrid steering shaft Custom steering links -1 1/4" .120 Chromoly -3/4" heims Rear: SOA Stock leaf springs (for now) Warrior shackle MORE wheel spacers: -1" spacer -5x4.5 to 5x5.5 conversion A few of the test runs: Dead Link Removed Dead Link Removed Last Chance...

Finally finished my long running Dana 60 axle swap. Build threads: Explorer Forum Demon4x4 Pirate4x4 Texas4x4 Non SAS build threads: EF Dana 44 Solid Axle Swap Project Thread EF 700r4/Atlas Thread Demon4x4 Dana 44 Install Thread Demon4x4 700r4/Atlas Install Thread This is my second attempt at a SAS, the first being a narrowed high pinion Dana 44 from a 1979 Ford Bronco. You can see that registry thread here. The specs for this SAS: Front Axle: 1979 Ford high pinion Dana 60 Summit Machine custom engraved flange covers and 35 spline drive slugs Warn 35 spline outer stub shafts Ford Sno-Fighter inner axle shafts Detroit SofLocker 5.13 gears 1350 U-joint yoke Stage 8 Dana 60 Spindle Locks Longfield...

The SAS has been complete for some time now so it is time to complete a registry. It is a daily driver for now and it has seen trips to Badlands and is getting ready to go to www.woolysoffroad.com. Didn’t turn out to bad……. Spec: Front end: 1978 F-150 HP D44 4.88 Gearing Warn Hubs Stock Brakes Custom Track Bar Mount Custom Coil Bucket Mounts 7* C-Wedges Wild Horses 5.5inch Rock Crawler Coils 78 F-150 Coil Buckets and Shock Towers Wild Horse Extreme Radius Arms (12” longer than stock arms) Rear Axle: 1978 F-150 9" 4.88 Gearing Spring over 4"block Shocks: BDS Extras: Nick's Driveline Custom rear drive shaft Custom front bumper W/Atlas Winch 5 Speed Swap Rear Bumper with reciever...

Wow It is finaly time to start my sas thread. 94' Ranger Supercab Splash Engine 95 roller 302 from a f150 GT-40Y heads GT-40 Intake 1" spacer for intake FMS roller rockers Comp Cam Pullys, brackets, timing cover, and watwepump from v8 explorer. Custom snorkle in the works (air cleaner 125 Massy Fergison) Summit racing all aluminum radiator and re worked radiator support Transmission Transfer case ZF-5 transmission from f-250 with 351 np-203 np-205 doubler from off road design 203 was from a chevy it was free Front axle 79 bronco hp dana 44 5.13 Yucon gears Aussie Locker Warn premium hubs stock axles for now Purple cranium 1/2 spider Rear axle Ford big bearing 9" mid 70's f series 5.13 Yucon gears Superior axles Compititon...

Finally got Some pictures, so I can finally do my write-up. Here is the Specs Axle: 76 F150 High Pinion Dana 44- This year has the 1/2" Axle Tubes Like a Dana 60 Narrowed 6" off Passenger side Passenger side Axle Shaft resplined by Dutchman Motorsports http://dutchmanms.com/ New: All Seals, Calipers, Pads, turned the Rotors, Spicer Ball Joints, SPicer U- Joints Warn Premium Manual Hubs Warn Diff Cover (not pictured) 4.56 Gears Open Carrier For Now Before Pics (3" VR James Duff lift 235s) Middle Before SAS (33x10.50 ATs, 4.5" Lift (3" VR James Duff+ Spacers and rear Spring over), Extended James Duff Arms) Steering: I purchased all the Steering link parts from RockWare (http://www.rockware.net/) 4 3/4" Heim...

swapped in a tj dana 30 using rustys offroad 4.5" coils springs on ballistic fab adjustable coil buckets set 6" ahead of the normal coil bucket mounting location. links are 2x2x.25" square tubing with poly bushings from ruffstuff and trailgear creeper joints on the other end. custom fabbed link mounts just ahead of trans cmember and extensive driver side frame modification for upper link so I could get the suspension characteristics I wanted. netted about 3" of lift overall which required cutting the engine crossmember out of the way of the panhard bar which is made with ruffstuff heims and 1 3/4" dom with .25 wall thickness. truck flexes really well, future plans are for a wagoneer d44 to replace the d30, using the same suspension...

Its come a long way but still has more to come i think...but here's where its at now 91 Exploder stock 4.0 w hooker headers (3rd one) built A4LD (still sucks - 3rd one) stock tcase (2nd one) front diff - 79 F150 crewcab D44 w 4.88s w aussielocker rear diff - 88 F150 8.8 w 4.88s w aussielocker front leafs are 2001 ranger rear packs, 2 packs per one front rear leafs are custom built pack from local spring shop -custom front crossmember -F250 hangers and shackles on front springs -F250 shock mounts up front -38.5x15x15 boggers -custom front bumper w 8274 warn -custom rear bumper -custom rockers 3.5"x3.5"x6' 3/8s welded in -2-12 pioneer subs -2 JL amps -JL components in all 4 doors -Pioneer premier 850 deck future...

I don't have near as many pretty pics as most of you, and no build pics, but it works pretty damn well. Using the generic forklift test the front tires come 42" off the ground before a rear tire lifts, and both rearts lift bfore the front will, which Im thought kinda odd. I don't have any wheelin pics, but the two supplied are from a trip to Tellico last year....poor things been on the road ever since. Any queastions, let me know. Coda

This was a buddie/customer build I recently did, I look at it as practice. My wife has a 98 XLT V8 explorer and in the spring shes getting a D30 and 33's. Run down on this build..... 1995 Explorer sport 4.0L m5ord and 1350 (eventually auto of some sort and most likely a 1354) 78/9 D44 5.13's Aussie, old school yukons (the good ones) with ctms 9" with 5.13 and spool 38.5x14x15 TSL's on Beadlocks (my old locks I built years ago) Radius Arm front with EB coils, maybe an 78/9 steering box (maybe) Before Pic, who's straight,clean ranger is that? Looks similar to Kyles beat and dented ranger:sonicjay: Got the old 8.8 out and a 9" in position. temporary on the mono leaf. Plan to change that later. But needed to get...

Here is the link to my car domain site. http://www.cardomain.com/ride/2209152 It has been a long three year process reasearching, building, and collecting. I still have a few things to decide on like shocks and my explorer axle swap on the back. I am just ready to take er out and drive it. I will post more pics of the suspension and crossmember and hopefully some action shots later. I welcome all questions and comments. This site is awesome and it would have been alot harder to accomplish without it.

It's the moment you've all been waiting for. It's not totally done all the way, but we just have minor things to do. What's left is: Rear brakes, attach front driveshaft, move the axle forward maybe 1-2", more welding, put Cory's steering on, then shocks. This should take less than a day to do. '76 EB D44 '76 EB 9" 35/12.50R15 BFG MT's 15x10 Rockcrawlers Coils from James Duff James duff extended radius arms Front and rear ARB's 4.56 gearing RS9000X shocks steering from CoryL Here are the new coils. They worked perfectly. I'll have more pics as the rest of everything gets together. I'll paint everything later too. Here are previous pics of the build up: My old axle...

Took 4 months but 1/2 that time was waiting for more $ to come in to finish up. Again with mods, I had to go the unbeaten path to see what works and what doesn't. Fortunately for me, this worked out well with no kinks I can think of. - Low Pinion Dana 44 from 2001 Dodge Ram shortened to use Wagoneer left & right inner shafts with stock Ram outer shafts. The good - Stock Ram Dual piston calipers 12" rotors - Chrome moly inner axle shafts - Low pinion chunk with great clearance to frame - Sealed hubs, 4x4 on demand, no more regreasing bearings, nut torquing etc. - Custom Radius arm design allowing me to unbolt passenger upper arm for 3 link radius arm or wristed arm setup for more articulation. The Bad - Sealed hubs, no more manual...