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91 Explorer on Dana 60's

Discussion in 'Solid Axle Swap Registry' started by Randall, June 11, 2013.

^^Searches ExplorerForum.com^^





  1. Randall

    Randall Demon4x4 Member

    Joined:
    March 29, 2000
    Messages:
    1,287
    Likes Received:
    1
    Trophy Points:
    48
    City, State:
    Mo. City, TX
    Year, Model & Trim Level:
    1991 Demon Edition
    Callsign:
    KF5ZXT
    Finally finished my long running Dana 60 axle swap.

    [​IMG]

    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 spindle bushings
    Lug studs converted to 9/16-18" to match rear

    Rear Axle:
    1979 Ford low pinion full float Dana 60
    Detroit SofLocker
    5.13 gears
    Crane High Clearance Dana 60 chromoly differential cover
    1/2 ton Chevy disk brake conversion
    1350 U-joint yoke

    Front suspension:
    14" 2.0 Racerunner dual rate coilovers, 250/350
    Custom 4 link & coilover hoops
    Lower links are 2.125 x .375" wall DOM
    Upper links are 2" Summit Machine aluminum links
    All heims are 1.25" Ballistic Forged Rod ends & RuffStuff jam nuts

    Rear suspension:
    Stock 4-door Explorer leaf springs
    2" Rancho Add-a-leaf
    Warrior 153 Shackles
    Ballistic Fabrication SOA kit
    Rancho RS9112 shocks

    Steering:
    Artec Industries Full hydro mount Dana 60 truss
    Reid Racing Ford Dana 60 steering knuckles
    Artec Industries Ultimate High Steer Arms
    Reid Racing Bronze upper kingpin bushings
    ARP high steer and spindle studs
    PSC 8" double ended hydraulic steering ram
    PSC Saginaw style steering pump, reservoir and power steering cooler
    CE120 orbital valve

    Other misc goodies:
    2002 Dodge 2500 Master cylinder
    Misc brackets from both Artec Industries and Ballistic Fabrication
    Custom engine crossmember

    Tires & Wheels
    16.5x9.75 H1 double beadlocks, recentered to 3.5" backspacing
    HDPE runflats
    Ballistic Fabrication Rock Rings
    37x12.50x16.5 Military Goodyear Wrangler MTS

    I'm sure I'm forgetting something.

    More pics:
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    Last edited: November 12, 2013
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  3. eganracing

    eganracing New Member

    Joined:
    July 12, 2013
    Messages:
    6
    Likes Received:
    0
    Trophy Points:
    0
    Year, Model & Trim Level:
    1994 Ford Explorer
    Awesome rig man! Are you gonna put a cage in it?
     
  4. OffTrac

    OffTrac Elite Explorer

    Joined:
    February 22, 2010
    Messages:
    4,041
    Likes Received:
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    Trophy Points:
    48
    City, State:
    Dublin, GA
    Year, Model & Trim Level:
    '01 Sport Trac 4x4
    Awesome build!

    Thank you for the details in your build threads and part numbers. I'm sitting on a '79 Sno-Fighter and D70 in the garage. This certainly helped my growing shopping list.
     
  5. Randall

    Randall Demon4x4 Member

    Joined:
    March 29, 2000
    Messages:
    1,287
    Likes Received:
    1
    Trophy Points:
    48
    City, State:
    Mo. City, TX
    Year, Model & Trim Level:
    1991 Demon Edition
    Callsign:
    KF5ZXT
    Thanks for the kind words. I do plan on a cage, just gotta firm up everything that I want integrated into it.
     
  6. obie

    obie Active Member

    Joined:
    June 13, 2012
    Messages:
    923
    Likes Received:
    5
    Trophy Points:
    28
    City, State:
    Northwest Indiana
    Year, Model & Trim Level:
    2003 Sport Trac 4x4
    Before I saw who posted the thread, my first though was 60 inch wheels, haha.
     
  7. Randall

    Randall Demon4x4 Member

    Joined:
    March 29, 2000
    Messages:
    1,287
    Likes Received:
    1
    Trophy Points:
    48
    City, State:
    Mo. City, TX
    Year, Model & Trim Level:
    1991 Demon Edition
    Callsign:
    KF5ZXT
    Hmmm, that's unfortunate, lol.
     

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