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91 xlt dana 44 hi-pin sas

Discussion in 'Solid Axle Swap Registry' started by MEANEXPLODER, October 5, 2009.

^^Searches ExplorerForum.com^^





  1. MEANEXPLODER

    MEANEXPLODER Active Member

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    Year, Model & Trim Level:
    91 XLT
    shortened Dana 44 hi-pin 5.13 gears detroit locker
    Ford 8.8 disc brakes 5.13 gears detroit locker
    4.0
    a4ld
    custom shafts
    rs7000 shocks
    cut down 79 bronco linkage
    35'' general mud terrain=poop

    upcoming very soon:
    37'' tires
    custom bumpers
    maybe an AM/FM radio so i dont have to whistle
    5 speed
     
    Last edited: October 5, 2009
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  3. MEANEXPLODER

    MEANEXPLODER Active Member

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    have no skills on computer

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    shock bushing shot... shocks were used freebies

    very near future mod
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    not that many miles on clutch either

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    new parts shed


    more action pics coming soon
     
    Last edited by a moderator: February 9, 2018
  4. IZwack

    IZwack Moderator Emeritus

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    Looks great!!

    My only suggestion is to stick with 35s or 36s - because even with 36s, we see quite a bit of D44 axle shafts snapping. So with 37's, you are probably going over the capbility of the D44 axle.
     
  5. crazyflights

    crazyflights Well-Known Member

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    Yea, looks good, Id leave it on 35s they fit great in my opinion.
    You will really like it with the 5spd.
     
  6. MEANEXPLODER

    MEANEXPLODER Active Member

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    Thanks..... just ordered softer coils, trailproof steering and trac bar..... the truck performs extremely well... the only bitch i have is the power steering sucks at low rpms.:rolleyes:... i need hydro assist i assume... wasnt sure if the road manners were that good w something like that..
     
  7. dangerrangerstx

    dangerrangerstx Member

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    have u got to take it wheelling ? i get to take mine tonight
     
  8. Fusion213

    Fusion213 Active Member

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    I think that looks great!
     
  9. MEANEXPLODER

    MEANEXPLODER Active Member

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    thanks fusion.... and danger, yes i have taken it wheeling up some pretty nasty ledges around my area and it performed great.... this sunday will be the first all day wheelin trip with it... i have some small kinks to work out and some interior work and stereo stuff to do but she should be ready to rock by sun morn. ill take some good action photos... need to get a digital cam.. my phone is all i got:p:
     
  10. justsomeguy

    justsomeguy Active Member

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    Nice Ex. I would'nt put that 5 speed in if it were me. I do not like how tall the 1st gear is. Maybe with 5.13's it's not that bad with 35's but with 37's you might smoke the clutch. I have had my clutch so hot trying to crawl over rocks it would'nt move anymore, I had to wait for it to cool to get off the trail. Just my .02 cents.
     
  11. MEANEXPLODER

    MEANEXPLODER Active Member

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    i appreciate the advice guy
     
  12. Freshmeat

    Freshmeat Active Member

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    Can you explain how you shortened the D44?
     
  13. MEANEXPLODER

    MEANEXPLODER Active Member

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    cutting the axle down

    first, i stripped the axle down to just the housing. then, i ground the weld the holds the cast axle outer on to the axle tube. After that, I heated the cast part and beat the shit out of it with a big hammer for about 4 beers and then after more heat and a touch more grinding.... it slid right of the tube. In my case i then measured 5.85'' off the end of the tube and set in up in my band saw and let it cut through. cleaned up the edges of the tube a bit and slammed the cast end back on with a bit of heat and my hammer (making sure the cast part is in the same orientation as it was at the start) laid down one of my super mig beads to reglue the cast part back to the tube and thats it. paint it black , blue or pink... whatever you like. then u end up with a shortened housing:cool:

    [​IMG] c01.jpg c02.jpg c03.jpg
     
    Last edited by a moderator: February 9, 2018
  14. MEANEXPLODER

    MEANEXPLODER Active Member

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    few action shots fartin around by my house

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    Last edited by a moderator: February 9, 2018
  15. Slowlyvverot

    Slowlyvverot Active Member

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    lol @ the bud can in the air
     
  16. redneck92explore

    redneck92explore New Member

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    i got a 92 xlt explorer and i want to lift it so i can fit 33's under it and if i flip my rear shackles what coils wold i need to get for the front?
     
  17. KJL

    KJL Active Member

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    What length right inner axle shaft did you use? I know the thread is two years old
     
  18. dkchrist

    dkchrist Well-Known Member

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  19. KJL

    KJL Active Member

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    I've read that a though times lol. TRS says exactly 6 inches. I've seen guys cut 5.95 and guys cut like 5.85.

    How exact does it need to be? I have seen on danas website that depending on what year eb axle it's out of, they came with slightly different length right inner shafts. Just curious what exactly to cut at.

    My boss has a dana 30 that is trusses up the a$$ that he might sell me. He says it's definitely stronger then the LP d44 that his EB bronco has under it. Wonding if I should pick it up if the price is right.

    What do you guys think?
     

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