Solid Axle Swap Registry | Page 7 | 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
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...
So i finally decided to post it i did not build the whole thing but i have had to redo a bunch of front axle geometry and go through all the lift stuff because of the hack owner before. ford 8.8 locked in rear with disk brakes with the PROPER master cyl 4.88's and new seals and bearings and everything. 66 bronco dana 30 front with yukon shafts 4.88's new seals and bearings and everything. warn manual hubs. brand new bilstien shocks all around custom shock mounts for rear and fronts. 5 speed with stage two clutch. 5.5 inch lift james duff front coils with james duff coil buckets. 6 inch drop pitman arm Extended radius arms . custom made trans/radius arm mount. custom made drivelines with new ujoints front and back...
well i finished my sas with the dana 30, went wheeling a few times, and riooed the front axle out. had the 44 sitting on the side of the house for a few months, and now its installed i used balistic fab radius arm and coil brackets, fabed up my radius arms with dom tubing for the uppers, and my old lowers. track bar is 1.5x .25 dom, and same tubing for my drag link. i used the stock tierod for now, but plan todo dom for tierod also. specs front axle dana 44 76 f150, 4.56, locrite rear axle dana 44 jeep wagoneer, 4.56s, disc conversion, chromo shafts, and yukon full spool. explorer: 93 Limited 5 Speed swap Electric fan harbor freight 12k winch 36in irok superswampers Suspension front rubicon express 6 inch...
i am located in lafollette, tn and have one with the following... 1986 Bronco II 1995 H.O. 5.0 carb'd 1975 bronco 44, 3.50, trac lock, stone crusher steering 1975 bronco 9", 3.50, welded, third (upper) link i used wild horses 5.5" lift coils 35/12.50 BFG's c-4 with c-5 output section all of this is about to change... i now have an AOD, NP 205, 2.5 Ton Rockwell axles i am about to add to the BII
I started out with a 01 explorer sport with 230k miles and now i have a 2001 frame with axles out of a late 80 f350 2003 body with 90k on it with stock drivetrain (for now). My plan is to either build the drivetrain i have now (4.0 sohc with a 5rod) or go to an lq4 engine and then 4 link it front and rear with coil overs within the next year or two. I will try to list all the parts i used but i know i will miss some so if there are any questions please ask. The swap has been one for about 8 months and i have put about 15,000 miles on it without a hiccup. No sway bars, trac bars or even a steering stabilizer (plan on doing a stabilizer before winter). This is my winter vehicle (for now) so i have my car i daily and drive my exploder on...
1992 XLT Well, I think I was second on this board to swap a 44 under my rig, behind Rick. '79 Bronco Dana 44: - housing cut 6" - pulled out longside tube from outer, cut 6" and press back on and weld - axle shaft cut 6" at LeJeune engineering in Victoria, BC - cut, tapered, and tig welded in the middle of the shaft - no problems - tierod cut down 6" and rethreaded - drag link cut and threaded to accept my Dana 35 TRE and adjusting sleeve - Dana 35 TRE used at pitman arm - coil buckets modified to accept James Duff 3.5" VR coils for EB - stock radius arms - '79 Bronco radius arm brackets - new Dutchman 1541 Alloy rear shafts for my 8.8" for 5 on 5.5" bolt pattern new this week: - '79 housing cut down 3" - BC Bronco...
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!!
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...
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...
Hey guys. Thought I would put this here so those of you who are doing SAS can use it if you need it. I am selling the steering setup on my SAS. Here is my Setup Description with Pics: more info on my SAS can be found here Steering: I purchased all the Steering link parts from RockWare (http://www.rockware.net/) 4 3/4" Heim Joints with a 3/4" hole (2 Left hand Threads, 2 Right Hand Threads) Weld in Threaded ends for the Tubing 1 1/8" Seamless DOM tubing I used 3/4" Grade 8 Bolts for all the Steering. Drilled out the Pitman Arm and the knuckles. I also used Misalignment Bushings for 3/4" Bolts from Poison Spyder Customs (http://www.spydercustoms.com/). I used 3 1/4" bushings and 1 3/4" bushing Steering Links THEY HAVE...
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