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1999 Ranger SAS (Dana 44/Ford 9 Inch)

Discussion in 'Solid Axle Swap Registry' started by bozone802, July 15, 2010.

^^Searches ExplorerForum.com^^





  1. bozone802

    bozone802 New Member

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    1999 Ranger XLT
    well here is what i started with:
    put 32s on it and wheeled it too hard for the stock shit to take, needless to say, i broke a bunch of shit
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    when the decision was made to do the sas i picked up a 1979 bronco as a donor:
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  3. bozone802

    bozone802 New Member

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    i started off the project by taking the bronco apart and keeping what parts i needed and selling what i could.
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    i kept the axles and suspension stuff
     
  4. bozone802

    bozone802 New Member

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    chop chop time!!!

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  5. bozone802

    bozone802 New Member

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    first order of business on the build was to plate the frame. as you can see i have good plates up front, but i now regret what i did in the back. i put plates on the inside of the frame in the rear when i should have just boxed it. so basically the plates on the inside of the frame were a good idea, but i should have boxed the frame around that for more strength.

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  6. bozone802

    bozone802 New Member

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    just a little fyi, the only welds i didnt do on this truck are the front frame plates, the rest i did myself after learning to weld when a friend gave me a 10min crash course. it is obvious where i started welding and what i welded recently because i am getting better everyday, and when i first started was on the rear frame plates so they basically look like shit! but its all good!
     
  7. bozone802

    bozone802 New Member

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    after the frame plates were done it was time for some rear crossmembers. i put a huge hunk of steel in the rear (not sure exactly what cause i found it in the scrap pile) and used 1.5in .120 wall tube for the rest.

    strap holding frame at the correct width:
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    2 crossmembers:
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    a few more of the rear:
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    and of the middle crossmember:
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    i also put small plates on the outside of the frame where the mid crossmember is to give me a little more metal to weld to:
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    and when i was done it looked like this:
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  8. Dezert_Dawg

    Dezert_Dawg New Member

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    Might wanna move this to the offroad projects forum. This is for finished SAS projects;)
     
  9. bozone802

    bozone802 New Member

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    it is finished, im just showing how i did it. havent got that far though seeing as uploading images takes forever and i dont really like sitting at my computer for that long... so ill get there soon dont worry
     
  10. bozone802

    bozone802 New Member

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    next on the list i mounted my front axle. just used the stock spring buckets and shock mounts from the bronco and the springs are a 4" rough country lift springs, and i used the stock bronco track bar and steering
    also up front is a FJ 60 steering box connected using 3/4 DD X 3/4 DD u-joint off the firewall into a DD shaft, then into a 3/4 DD X 11/16-36 spline to fit onto the steering box.
    there is also a new power steering pump with new custom lines to fit onto the FJ box.

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  11. bozone802

    bozone802 New Member

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    Rear end:
    used 4 front leaf spring hangers to mount the leafs, then got a new yoke and u-joint to hook up my stock driveshaft and set the pinion angle, then mounted the shocks, mounted removable mud flaps, then i put the bed on, chopped it a bit and put on some cheap spray on bedliner, then i mounted a temporary bumper and had a hole torched in it for a hitch cause what good is a truck that cant tow? and lastly i mounted my licence plate with bolts with leds in them to light up the plate

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  12. bozone802

    bozone802 New Member

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    i also did random things like put in a 10 inch sub and mount the cb antenna on the toolbox

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  13. bozone802

    bozone802 New Member

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    now my truck is sittn pretty, well actually it has a bit of a drivers side lean, but whatever, no worries ill tweak that sometime in the near future. and it pretty much looks like a billboard but it already looks ridiculous, why not make it a little more!

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  14. 94 Crawler

    94 Crawler Active Member

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    Hey man your truck looks great how dose that bronco box work for ya. I need to try one on my wifes Montero but I've been to buisy with my Volksrod project to even think abought a 4wd.
     
  15. TarHeel085

    TarHeel085 And den

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    It does look good! where did you get the steering shaft made?
     
  16. Ranger99OR

    Ranger99OR New Member

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    Hey there,

    I have been a fan of this build for a while. I have been wanting to do an sas for a while, and have recently decided to start planning, I have a few questions.

    First, did you have to change your spring perches on your axles?

    And are the spring mounts(on the frame) fabbed up or the stock ones?

    I am just debating if I need to make new hangers for the front and rear or not.

    Thanks.
     
  17. yostyexplorer94

    yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

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  18. +RABBIT+

    +RABBIT+ New Member

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    looks like mig
     
  19. Ranger99OR

    Ranger99OR New Member

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    Ranger SAS Help

    I love this truck and how he did everything. I dont know if I will get a response from him but does anyone know if he had to make and reset his mounts on his 9 inch axle for the springs. I am wondering if using those hangers gives him the right width or not.
     
  20. bozone802

    bozone802 New Member

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    wow that was a long time ago i pretty much forgot about this. i had to cut the old perches off the 9 inch then weld new ones on.

    thanks for liking it! I like it too, and its not bad for being a learning experience for me. now there are lots of things i would have done differently. i learned how to weld on this truck and amazingly non of my first welds have broken (they are still there).
     

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