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94 Sport Full Width Dana 44 and 9 inch

Discussion in 'Solid Axle Swap Registry' started by svande8952, January 13, 2005.

^^Searches ExplorerForum.com^^





  1. svande8952

    svande8952 Active Member

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    Ok it's finally looking like something. This thing should be complete by the end of next week, so I am posting this in the registry instead of the projects section, I hope that's OK with everyone.

    Front:Full width Dana 44 from a 78 Bronc with 4.88s and a Lock Rite
    Wild horses coils, custom drag link and radius arms. Bronco buckets and stock track bar.

    Rear: Full width Ford 9 inch, with 4.88s and a EZ Locker, stock springs and 4 inch blocks.

    No cutting down here. There are pizza cutters on her right now, but I'm picking up the 35' Muds tomorrow.

    [​IMG]
    [​IMG]
    http://memimage.cardomain.net/member_images/6/web/726000-726999/726969_24_full.jpg
    This is the wristed radius arm on the pass side. Looking ugly with no paint.
    [​IMG]
    Thanks for looking!!!!
     
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  3. RangerX

    RangerX Elite Ranger Staff Member Moderator Elite Explorer

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    Full width rules! :thumbsup: What backspace will you run on the wheels? What brand of 35s? That rear tire is a TRUE pizzacutter! What size is it!?! :confused:
     
  4. NOTAJP

    NOTAJP Moderator Emeritus Moderator Emeritus

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    How did you compensate for the full width? Where are the radius arms mounted on the frame? Did you space out the coils?
     
  5. svande8952

    svande8952 Active Member

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    I spaced in the coils and spaced out the buckets. and I am going to run stock backspacing on the wheels and let the mud fly!!!!!!!!!!!
    I'm getting BFG Mud terrains, the tires in the back right now are from a 47 jeep or something. The only number on them is 75, I don't know what that means, but I measured them and they are 28 1/2 inches tall.
     
  6. bmxking5

    bmxking5 Well-Known Member

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    Looks good so far. Congratulations on almost being done. :thumbsup:
     
  7. X-1

    X-1 Elite Explorer

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    looks good, I am currently getting parts together to put a dana 30 under my 94. Are all sports green?
     
  8. FROADER

    FROADER Moderator Staff Member Moderator Elite Explorer

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    Nice work on leaving the axles full width!! Looks good so far, can't wait to see it with the 35s on.
     
  9. Trckmagik

    Trckmagik Ole Bag Moderator Emeritus

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    I would like some closeups of your front end install. I am currently putting the same axles under my 1992 Explorer.
    I need pics of the radius arm brackets at the frame, coil lower mounts and the buckets. Thanks so much.
     
  10. svande8952

    svande8952 Active Member

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    Here are the radius arm mounts, they are just tacked in place right now. I am going to Box the frame in that area and then weld the mounts back on.
    [​IMG]
    Here is one with the new meats :D
    [​IMG]
     
  11. FROADER

    FROADER Moderator Staff Member Moderator Elite Explorer

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    Action shots, actions shots please... :)
     
  12. Ford_Racing_Guy

    Ford_Racing_Guy Well-Known Member

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    wow that looks very menacing with those full width axles :D :D
     
  13. svande8952

    svande8952 Active Member

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    Here are the new radius arm mounts I made. The other ones were too low and looked like shit. As you can see, I boxed the frame above the RA mounts for extra strength. I also welded a plate above the RA mounts for a future crossmember or skidplate.[​IMG]
    [​IMG]
    [​IMG]

    This is just a pic of the teuck how it sits now. I am only waiting on the rear Driveshaft now.
    [​IMG]
    Yes, those are the nurf bars sitting on the ground. I am going to weld those on tomorrow.
    This has been a great project and I could never have done it without this website. I have spent hours researching this site and soaking up as much info as possible.
    Fot those of you who want to know, here is an abreviated cost breakdown for the entire project. I bought alot of the small stuff on ebay.

    HP Dana 44 from 78 Bronc--------320.00
    Ford 9inch-----------------------Freebie :D
    Gears and lockers for front and rear-787.00
    Installation for Dana 44 gears-------175.00
    Tires-BFG Muds 35x12.5x15---------880.00
    Drive shaft-rear--------------------389.00
    Misc welding-----------------------400.00-est.
    Warn hubs-------------------------55.00
    C bushings-7.5 degree--------------40.00
    Jonny Joints for RAs-----------------40.00
    Tubing for rear bumper and nerfs-----80.00
    Wild Horses 5.5 lift EB springs--------Freebies
    3.5''Lift blocks for rear-------------------Freebies

    I'm sure there is more stuff I forgot, but these are the major parts.
     
  14. rino351

    rino351 Well-Known Member

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    That thing is MASSIVE!!!
    How did you manage all the freebies?

    Looks great so far!!
    Action shots-YES!!
    :D

    OBTW, I've heard that w/ fuul width axles, the driveshafts and some other stuff doesn't align correctly. Was that the case for you or is that a false statement?
    Thanks
     
  15. svande8952

    svande8952 Active Member

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    As for the freebies, I have alot of freinds who have been doing this for a long time, and I had to "work off" the 9 inch by helping a guy put a 350 in his Land Cruiser.

    I don't know what everyone's hang upis with full width. I had no problems with alignment, other than the coil springs. I just had to rotate the pads about 90 degrees so the spings would be verticle to the buckets. Other than that, no problems.
     
  16. Positive Vibes

    Positive Vibes Elite Explorer

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    Sweet!!

    Looks great! Signing up for future posts!
     
  17. svande8952

    svande8952 Active Member

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    Flex anyone?
    [​IMG]

    40 inches. Now I can order the shocks and she'll be ready to rock!!!!!!!!
    [​IMG]
     
  18. dman726749

    dman726749 Well-Known Member

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    Nice :D
     
  19. rino351

    rino351 Well-Known Member

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    That is a beautiful site!!
    :D
     
  20. Trckmagik

    Trckmagik Ole Bag Moderator Emeritus

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    Did you need to space out the Coil Buckets in order to match up with the full width axle?
     
  21. svande8952

    svande8952 Active Member

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    No, I turned the pads in that the springs sit on. Then I relocated the holes so I would have 2 hold down bolts for the spring. I also welded the pad to the rear part of the radius arm for extra strength.
     

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