Solid Axle Swap Registry | Ford Explorer Forums - Serious Explorations

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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
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...
Hey everyone, finally decided to post my results here. My setup includes: 1995 High Pinion D30 Spring hangers and drag link(3/4" heims) by CRL Customs 1979 Jeep Grand wagoneer stock leaf springs 1993 Explorer steering box Rubicon Express RE1550 22" long brake lines (bolted right up to hard lines) Rancho RS 5036 front shocks SOA in the rear there are more pics here http://www.cardomain.com/memberpage/223222/2
k guys here how it went..... front end: hp dana 44 (from 79 f150) rear 4 in lift springs from the f150, but we took out 2 leafs... used steering from the f150 moved the axle forward 3 inches... rear end: ford 9in from same truck moved the axle back 3 inches... it turned out real good, all we need to do is get driveshafts which will be done tomorow.... will post pics tomorow when i drive it home:)
KEEP IN MIND, EVERYTHING THAT FOLLOWS IS FROM MY BUILD ON ANOTHER SITE, SO ITS PRESENT TENSE WHEN I DID IT....BUT, IT SHOWS FULL BUILT MORE OR LESS. so, i decided to obliterate my truck in an attempt at making something better. so far so good, im happy to say. this is blackfoot(what i named my truck (no its not corny). so ive seen people chop the rear end off their rigs to make a pick-up style rear end. i really liked the idea, and decided to go forward with it on my own. i have no fabrication experience at all, im majoring in welding in an attempt to learn fabrication, but i guess i would learn best by doing it. so, after much contemplation, i decided to do this to my explorer. i had somewhat of a different idea though...
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...
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...
well...I've got a seepin brakeline...and need to mount tabs to secure the brakelines at the shocks...and to add friction modifyer to the rear axle...and fix the one middle pillar on the exo cage...buy the tierod ends and get the steering in.. BUT...I got it out..and flex tested it....unbeleivable..I need a bigger rock in the yard...when Im flexin the rear..the driver front it totaly compressed...but the pass side is about 1in from max.. when Im flexing the front the rear has about 2in before the pass side is at full compression..and the driver side is about 2in from max droop.. but its close enough to done for me!!
Ok - after about 4 months of planning and tinkering, Tramp is out! Details: 4.56's Detroit rear, EZ Locker front 37" Goodyear MT/R's 1.25" spacers that convert the rear to 5x5.5 D44 from a '75 bronco James Duff coils, shocks, RA mounts F150 outers up front Steering by CoryL Customs This project was a huge undertaking. I started with a stock '93, added 31's, then a 3" bodylift, then a 5.5" superlift and 35" Xterrains. After too many issues with the front end, I decided to swap. Bought all the parts I needed, but ran into many problems along the way. From brake lines to transmission crossmember, they cam about once per week. Here is a pic of the crossmember cut and braced... I have since added a 45 degree brace...
Ok this is like my first time posting i have used this website for awhile now and there are alot of great tips on here so thanks a bunch everyone Here is my SAS X Dana 30 HP Custom long arm built from a jeep setup Custom crossmember Custom explorer coil buckets for jeep springs Stock jeep track bar Stock jeep steering (tie rod end swapped for pitman) 6" Drop pitman arm 8.5" jeep lift springs SOA w/2wd s10 springs total of 10" lift (no block:D) 33" BFG M/Ts soon to be 33" BajaClaws Thanks for looking
I just realized I never registered mine... D44 Ft D60 Rr with disc brakes Leaves front and rear 35 in Swampers and 5:13 gears BW4406 Tcase thanks to all the people on this site that helped, Couldnt have done it without this site. Still working on perfecting it, needs the cage and bumpers finished...but here it is:
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...
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!
Heh, I finally can post in the registry. :D Heres the nitty on Emily D44 Front: Fullwidth 76 f-150 drum brake high pinion D44. Converted to disks with 79 f-150 flattop outers. 5.13 Yukon gears open carrier Warn manual hubs GLO diff cover, 1/2" plate and stuff. 9" Rear: Fullwidth 78' F-150 9" 5.13 Yukons with richmond 31 spline spool. 36x12.5x15 TSL-SX Stock wagoneer leaf spring over in front, stock explorer spring over rear. Superlift 5.5" lift extended lines, extended an extra 16". Shackle foreward F-150 tierod, reversed explorer drag link with no modifications needed. It isnt the prettiest or the most high dollar rig around, but if my driving performs as well as it flexes im sure I can hold my own with...
For my 10,000th post I guess I will start my SAS registry now that the truck is done. :thumbsup: Section525's SAS Build thread Specifications Front '83 Wagoneer LP D44 JCW 5-leaf Springs (Stockers) Detroit EZ Locker Spicer 4.88 gears Warn Premium Hubs Rock Equipment Super Boy Howdy Fabricated Knuckles Sky Manufacturing High-steer arms Pro Comp MX6 Shocks Rear Stock 8.8 SOA Sierra 4.88 gears Detroit EZ Spidertrax 5x4.5 to 5x5.5 adapters Stock shocks The Build The LP D44 came out of a 1983 Jeep Wagoneer. I was there when the guy pulled it out from under the Jeep. It was nice to see the condition of the donor before buying the axle. I began the tear-down of the axle and everything looked good inside. :cool: I used TT Fab...
Hey guys, I just pretty much finished the major fabrication of my SAS on my 92 Sploder, still need tires cuz I dont think 32s will look too good. It is a Dana 30 (dont laugh), and Im not sure how much lift it is but I need a new front driveline. It barely bolts up to the axle fully extended. My question is what did you guys do for your drivelines?...did you get it custom made or what? I have some more pics but here is a couple if my truck , if it helps...thanks.
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