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MyNameIsAric's 98 FULL width SAS

Discussion in 'Offroad Projects' started by mynameisaric, April 8, 2007.

^^Searches ExplorerForum.com^^



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  1. mynameisaric

    mynameisaric Well-Known Member

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    City, State:
    Bolingbrook, IL
    Year, Model & Trim Level:
    98 XLT
    I will keep this first post updated with my progress so people don't have to weed through all the boring crap associated with these buildup threads.
    So far I have:

    Front axle:
    Dana 60 35 spline kingpin high pinion from a 79 f-250/350
    detroit locker
    dedenbear knuckles
    5.38 gears
    alloy usa shafts
    longfield u-joints
    warn hubs (should have went with drive flanges)
    high steer arms with full hydraulic steering

    Steering:
    2x8 double ended cylinder from surpluscenter.com
    steering valve out of an old forklift
    misc. hoses and fittings from surpluscenter.com

    Rear axle:
    Dana 60 30 spline low pinion from a 79 f-250/350 (should have went with a 14 bolt)
    full spool
    5.38 gears
    Disk brake conversion

    Tires/wheels:
    16.5" hummer h1 8 bolt double beadlocks recentered with custom stazworks centers.
    36x12.50 wrangler rt II 6 ply military bias tires(sucky but cheap)

    Things I need still:
    new rims and tires and hopefully she wont shake so bad at 60mph.


    Got axles
    [​IMG]
    [​IMG]
    Cleaned up axles
    [​IMG]
    Welded wheels
    [​IMG]
    [​IMG]
    [​IMG]
    Got a new truck so i can dismantle the explorer and tow it around when i'm done.
    [​IMG]
    Welded Diff covers
    [​IMG]
    [​IMG]
    Rear axle almost done
    [​IMG]
    [​IMG]
    Front axle almost done
    [​IMG]
    Rear axle under truck
    [​IMG]
    Welding up rear driveshaft (yes, it is square)
    [​IMG]
    [​IMG]
    Machined parts for the upper control arms
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Made coil buckets
    [​IMG]
    Made lower control links
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Mocking up Front axle and welded up hydraulic ram mount.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Got myself a forklift orbital for my hydraulic steering
    [​IMG]
    [​IMG]
    welded on lower control arm mounts
    [​IMG]
    Dropped the front IFS
    [​IMG]
    Sent it to the scrap yard
    [​IMG]
    IFS gone
    [​IMG]
    Front axle starting to go in.
    [​IMG]
    [​IMG]
    [​IMG]
    off jackstands
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Took out the A/C system and cruise control. Also removed ABS brake controller, but I ended up having to put it back in later for the speedo to work.
    [​IMG]
    Mounted new/slightly larger fluid reservoir for the hydro system.
    [​IMG]
    Mounted the stock power steering cooler for the hydro system
    [​IMG]
    Got this mounted in the engine bay where the A/C junk used to be
    [​IMG]
    Had to chop down this thing first though.
    [​IMG]
    Made some tie rods out of 100% grade A beef.
    [​IMG]
    Installed hydraulic ram and tie rods.
    [​IMG]
    View of the filter, and you can see the high pressure hose running from the pump down to the steering valve.
    [​IMG]
    This is how i connected the stock steering wheel to the steering valve. 3/8" swivel
    [​IMG]
    Better view of the steering valve.
    [​IMG]
    Poor planning caused track bar issues
    [​IMG]
    Made a new track bar bracket
    [​IMG]
    Cut off first track bar bracket
    [​IMG]
    Plated for good measure
    [​IMG]
    Welded on new track bar bracket. Still had minor interference so i move the axle forward another 1/2"
    Also started putting on shocks.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Tacked a tone ring to the rear d60 carrier
    [​IMG]
    Reinstalled tone ring sensor so i can get speedometer back
    [​IMG]
    blah blah blah tidied things up and poof.... an explorer that can only go 55mph now. If you have questions, just ask or PM me.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
    Last edited: September 30, 2011
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  3. FROADER

    FROADER Moderator Staff Member Moderator Elite Explorer

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    Sounds awesome. Why don't you just use the LP44 since you already have it?
     
  4. mynameisaric

    mynameisaric Well-Known Member

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    i might, but the ground clearance and ring/pinion strength make me want the hp, and i dont want to spend all this money and regret ANYTHING. since the locker/carrier, shafts, knuckles etc. would all transfer over to a hp 8 lug, it doesnt sound like a bad idea, but then i would need a new ring/pinion, master install, setup costs and have to cleanup another housing, so i would rather find a hp to start with.
     
  5. Mud Bug 94

    Mud Bug 94 Well-Known Member

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    use ur lp to mock everything up...then ull have time to get a hp44...
     
  6. zainyD

    zainyD Active Member

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    '96 Ranger 4x4 XLT
    I would use the LP D44! You've already bought it and got it for a good price. I would run it until you can find a Hp D60. There's really no reason to swap in a HP D44 in it's place, just go straight up to a D60.


    I would not suggest using a spool in the front unless you want increased steering effort. A LockRight or Aussie locker would only be about $100 more than a full spool would be and the steering effort would be a lot less.

    Good luck!
     
  7. mynameisaric

    mynameisaric Well-Known Member

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    i am NEVER using a lunchbox locker again. both of my powertrax failed on me, and are the main reason i'm doing the SAS. This winter was a drag with one wheel drive. the rear never locks up and the front never unlocked(even with the driveshaft taken out) so i blew a cv shaft.. litererally. it went "POP!", grease flew everywhere and it just sort of clanked around until i came to a stop and then i got out and saw it dangling there. So I may use a detroit up front if anything. i was thinking about an ox, but i dont think i want to spend almost 1k on a locker. then again, whats another 300 hundred bucks ontop of a detroit when you're talking about a 5-6k buildup?

    I just don't want to invest any money into an axle i'm not going to use. I plan to spend alot of money on this, and i'm not going cut corners, but i'm also not going to spend money twice.
     
  8. SkanlaxJMO

    SkanlaxJMO Well-Known Member

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    looks like a good buildup.
     
  9. Premier

    Premier Explorer Addict

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    Pimpin :cool:
     
  10. 21robbie21

    21robbie21 Elite SPort

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    To clean the "nooks" on my housing i just sandblasted the entire thing and it cleans most of those out. Just take the axle to your work and sandblast it.
     
  11. dirtbro

    dirtbro Active Member

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    sounds like a sick build but do you really want a spooled front if it is going to be a daily driver...?
     
  12. mynameisaric

    mynameisaric Well-Known Member

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    hubs will take care of the spool while its on the road. if i go with the dana44, i will probably go detroit, but if i go 60, then i like the idea of a spool... just means i'll have to add hydro assist :D
     
  13. dirtbro

    dirtbro Active Member

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    gotcha...should have thought about that before...good luck on the build:thumbsup:
     
  14. mynameisaric

    mynameisaric Well-Known Member

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    instead of the TJ radius arm deal, i saw the following images on JoshC's SAS #2 thread, and i really like this idea. It looks alot easier to fab up. Do you guys have any opinions on this setup? Whoever has this rig is using the rims and axles i want to use too.
    [​IMG]
    [​IMG]
     
  15. sn0border88

    sn0border88 Master Apprentice Elite Explorer

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    thats a early bronco over on pirate. Post the pic over theere and im sure the owner will turn up. Its on hummer rims as well.

    Curious, you want to do disk brake conversion, a detriot locker and an 8 lug rear. Why not 14b? You can get them for the same price as the 60, its stronger and detriots are everywhere for them. You can probably get one with one already in it.
     
  16. mynameisaric

    mynameisaric Well-Known Member

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    well i already have the d60, and if i put it together, i know the quality going into it, and i'm sure a d60 will be plenty strong for my application. I'm only running 37 or 38's.

    besides.... who wants cheby parts on their truck? :D
     
  17. Mud Bug 94

    Mud Bug 94 Well-Known Member

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    im only runnin 35s...and you read my thread...
     
  18. '97 V8

    '97 V8 Well-Known Member

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    If you put all the costs together, it would be cheaper to buy (and stronger) a stock d60 then to build the hell out of the 44. Occasionally some 78-79 60 housings go on ebay and sell for around 350-400. I would def go that route if i had to do it all again.
     
  19. Mud Bug 94

    Mud Bug 94 Well-Known Member

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    haha i already have one:smoke: :bsnicker:
     
  20. mechanix

    mechanix Got beer?!?!?!

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    I agree with zainyD on the use of a spool in the front end. It makes the steering alot harder and puts alot more force on the drive line than it really needs. Aussie has a good reputation around and they are life time garunteed. I think your problem with your other lockers is they where in a full time 4x4 axle (cv shafts never had a way to unlock from each other) and they was always fighting each other even if you was not in 4x4.

    Eric
     
  21. mynameisaric

    mynameisaric Well-Known Member

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    you haven't done it the first time. lol:D

    But i am definitely looking into a 60. I'm set on my 60 rear, so i at least have something to work on for now.

    Anybody have any thoughts about that disc brake conversion kit on pirate? I think i will be ordering that shortly.

    on another note, the weather around here isn;t cooperating. i have an operating temperature minimum of 45 degrees, and its still in the 30's around here. So as soon as it warms up a bit more, you will see more progress. I get paid friday, so i will probably order some goodies for the 60 then.
     

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