Solid Axle Swap Registry

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...

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...

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...

well i finally got the thing driveable. i am still lacking a front driveshaft (that is why i am bearly flexing in the pic, i had to creep up in 2wheel) the tranny pan has a slight leak, i need to replace a rear wheel seal but other then that its rockin. the 351 has about 55 psi when cold and about 25-30 hot. the motor runs cool, not sure how cool because i dont have a temp gauge but i am running a large electric fan, a rigid fan off the water pump, and a 160 degree thermostat. its a four core aluminum radiator that is the the same size as an explorer radiator. i am running the tranny cooler in the radiator and an aftermarket one. there are still quite a few little things i have to pick at to get right but its basically done...

well here is what i started with: put 32s on it and wheeled it too hard for the stock **** to take, needless to say, i broke a bunch of **** when the decision was made to do the sas i picked up a 1979 bronco as a donor:

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

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

I have a 98 explorer xlt that I bought when I was 15. Shes still running but last year I decided to straight axle it on a budget. Had a dana 44 but couldn't find any parts for it in any local junkyards. So I scrapped it and picked up a dana 30 cheap that is holding up surprisingly well. Front axle- High pinion Dana 30, 4.10 gears, xj shafts, lockright locker Rear axle- 31 spline 8.8, 4.10 gears, welded Suspension- Front is SOA with waggy springs, AAL, shackles, rear is SOA with AAL and shackles, skyjacker nitros all around 3 inch body lift 2 inch wheel spacers 4.0 OHV, automatic, bw1354 manual case Extended brakelines Steering- 94 explorer box, custom shaft, 1/4" steel plates on both sides of the frame, sleeved...

Here is the build up of my Explorer for a SFA. The axle I used is a Dana 30 off of a Jeep. I bought the axle in December, so I had plenty of time work on it. I had it regeared to 4.56's. I also installed a Dead Link Removed. I've already got a Dead Link Removed in the 8.8. I put these diff guards on the front and rear too. Cory uses some pretty tough stuff. All of the links on the front axle use Hiem joints for the connections. The links are all customs made by Cory. All of his tubing used on the axle is 1 1/2" OD, 1/8" wall (I think). The coil buckets we used came from a race car magazine. They are adjustable for ride height. After 3 months of having the truck, he...

Completed! Specs: 1997 Ford Explorer Sport 4x4 SOHC 4.88 Gearing 35" Procomp Xterrains on 15x10 Black Rockcrawlers Rear Stock Axle SOA Extra Leafs to Match Front Height 5 on 4.5 to 5 on 5.5 wheel adapters from Performance Wheel and Tire Powertrax No-Slip Front 1976 Bronco Dana 44 Lockright Locker Stock EB radius arm - Passenger side wristed 7* Radius Arm Bushings Wild Horses 3.5" VR Coils Dual Shock Setup with Explorer Procomp ES3000 shocks F-250 Shock Mounts Custom Radius Arm Brackets CRL Customs Bigg Dawg Steering Ford Ranger Steering Box Drop Pitman Arm Before (4" Suplerlift):

Hey guys... this is humbling to be able register here. I know that there are like 4 guys going to register very soon. lizardtrac, morrisey0, FMExplorer, muskrat, jeffseal... i know there are others, but these are the guys who have helped me out in so many ways. not to mention coryl - the guy is an inspiration. Started with 1995 XLT with 170,000 on the ticker and a tax refund check! (thanks uncle Sam) I had torn up 2 sets of wheel bearings in the past year, needed to replace control arms, ball joints, my fourth cv axle... in all it was going to be nearly $1k in parts to replace parts that were just worn out... so the old noggin started working. wife got her a new/used car for her and gave me the go ahead to tackle this project. Ill...

Solid axle Navajo.. I did my Navajo in early 2001. My chain of events was: installed ARB in front d35. Blew ARB up after using 2 times. When ARB was pulled, and a open diff was installed, bearing caps on d35 pumpkin broke. Decided enough was enough - I also had a Superlift 5.5" lift on it, and was breaking/bending brackets every few months. Pull the navajo into the back of a local shop, and started cutting off the TTB components. We cut 6" off a 1979 Bronco D44, from the passenger side (long tube side). Sent axle to Dutchman for cutting down. Also bought 5x5.5" pattern axles for the rear 8.8, and upgraded to disk brakes at the same time. Rear was running the Superlift SOA kit, which gives 5.5" of lift. Added 2" more lift...

A friend and I completed this swap in four days, which is a good thing considering this is my daily driver. Here's a quick run down of the mods to the front end: -'71 EB D44 sandblasted and powder coated -4.56 gears w/ ARB -3/4 ton chebby inner shafts w/ '78 bronco outers (297 U-joints) -chebby disc brake swap -3.5" wildhorse springs -F-250 shock mounts w/ RS5000 shocks -custom steering using 1-3/8" D.O.M tubing 5/16" wall w/ full size chebby TRE's -'76 f-150 coil buckets -skyjacker radius arm mount (it was already on the truck) __________________ Pictures

I just completed my SAS in one weekend from start to finish. If any one has any questions, I will be more than happy to do my best to answer them.

Well I have been finished with my SAS build(who am I kidding no one ever finishes do they?)for about a year and a half so I guess some info and pics are in order. I wouldn't have been able to complete this build if not for this site and doing alot of reading. this site is so valuable to any explorer owner!:exporange here is a list of parts and mods: High pinion Dana 44 front full width stock axles open diff Ford 9 inch big bearing full width rear stock 31 spline axles,detriot locker 10.5" Dom .250 wall extended radius arms and kustom mounts with 1" jonny joints James duff long travel shocks front and rear(35" extended) Bronco Graveyard 5.5" Deaver front coil...