1998 Mountaineer / Red Dragon (SAS & SOA Project)

Hello there,
I have been a long time follower here on Serious Explorations. This site has helped me out countless times with my explorer. I don't usually post much, but now that I am starting a project I would love to share it with everyone. Over the next year or so i'll posting my progress with the Merc (Red Dragon).

Stats on the Merc:
1998 AWD 5.0 V8, everything is stock .....for now!

Plans for the Merc:
SAS
SOA
BW 4406 t-case swap
dana 44 front
stock 8.8 rear-with adapters for now, planning on doing an ultimate 8.8 kit in the future (scrapped my rear dana 44 idea with some thanks to fellow members)
front off road bumper
rear bumper with tire carrier
4.88 gears
lockers front and rear
winch
and probably countless other mods

 

[ShinySquirrelXLS]

First Parts orderd for the Merc

Just oreded some Monroe hood lift supports. The mounty needs them badly. Previous owner has been using a piece of gas pipe to hold the hood open and now the insulation under the hood is all ripped and falling apart.


http://http://www.rockauto.com/catalog/moreinfo.php?pk=61259&cc=1305212

The spending begins

 

[dersch6221992]

Tell me more. what route do you plan to go with your SAS? do it yourself? or have help?

i have a 2000 i am considering doing a sas on

 

[bronchole]

You can check out my regestry (link in my sig) for any ideas.

Most of the SAS's here are done on 4.0 engined rigs. From what I understand the primary difference is the steering box. I have a link to the box that was used in my rig in my regestry.

Good luck with your project.

 

[ShinySquirrelXLS]

Well a buddy and myself plan on tackling the entire project. Soo ill be doing it myself and with help . Im trying to stay within a budget of about 4-5 k, including tires and rims. Im planning on using some waggy dana 44s front and rear. Leafs up front with a high steer setup.

Most of the info I plan on using will be compiled from alot of useful info here on the site. As I go along ill be posting specific details

http://http://www.explorerforum.com/forums/showpost.php?p=2698692&postcount=5

Here are a few that I plan on following pretty closely.

http://http://www.explorerforum.com/forums/showthread.php?t=311454&highlight=straight+axle

http://www.explorerforum.com/forums/showthread.php?t=303902&highlight=98+merc

http://www.explorerforum.com/forums/showthread.php?t=168723&highlight='99+full+width+SAS

 

[ShinySquirrelXLS]

You can check out my regestry (link in my sig) for any ideas.

Most of the SAS's here are done on 4.0 engined rigs. From what I understand the primary difference is the steering box. I have a link to the box that was used in my rig in my regestry.

Good luck with your project.

Awesome! Thanks for the info. Ill be sure to check it out when I get to that step.

 

[dersch6221992]

definitely staying tune for this! whens the official start date?

 

[bronchole]

Any particular reason you are going leaf spring instead of coil? I can tell you the ride sure is nicer.

 

[FROADER]

I'd scrap the rear d44 idea and keep the 8.8. If you're keeping it full width, find a full width 8.8 or 9."

 

[ShinySquirrelXLS]

Any particular reason you are going leaf spring instead of coil? I can tell you the ride sure is nicer.

To be honest i figured it would be cheaper, trying to keep a budget. Is it that much nicer? what kind of wheeling do you mostly do? i want a nice ride if leafs are that uncomfortable coils might be my better option ?

I'd scrap the rear d44 idea and keep the 8.8. If you're keeping it full width, find a full width 8.8 or 9."

Only reason why i was going to use the waggy 44s is because they have a wheel mount surface of 61 inches? and a full size 8.8 is 65.5 inches? Plus my buddy rolled his waggy and is possibly parting it out soon. He might give me good deal on the axles.

I will probably change my axle choice if i do coils...

 

[FROADER]

Only reason why i was going to use the waggy 44s is because they have a wheel mount surface of 61 inches? and a full size 8.8 is 65.5 inches? Plus my buddy rolled his waggy and is possibly parting it out soon. He might give me good deal on the axles.

I will probably change my axle choice if i do coils...

The front axle will be perfect, but the back is less desirable than your stock 8.8.


This is a Ranger, but Matt used leaf springs as soon as he could switched to coils. Page 14 has finished product with leaf packs.

http://www.explorerforum.com/forums/showthread.php?t=125858

Rebuild thread with coils.
http://www.explorerforum.com/forums/showthread.php?t=219458

 

[bronchole]

If $$$ is a major restriction than I guess I understand your intent to use the same spring setup as the donor vehicle.

It's hard for me to compare the ride comfort because the last front leaf spring rig I took a ride in was a 1971 F250 4X4. Not ment for comfort

I agree with Froader, going with an 8.8 or if you don't mind losing the ABS going with a well built 9" is the way to go. Personally if I were building from scratch I would be going with a D60HP in front and a GASP!!!! 14 bolt in the rear.

 

[ShinySquirrelXLS]

$$$ isn't a huge issue. The project will just take longer to complete. But I would rather do it right the first time than go back and change things up.

Coil springs have a great ride. I Have a Heep on 6 inches and 33s. I go wheeling with that instead of my explorer. I want to be able to proudly wheel a FORD. maybe I should just suck it up and spend the extra $$ and do a Y link. This might narrow me down to using a tj 44, dana 30s don't like 35 inch tires.

Froader and bronchole, you have both made me rethink my project (for the better) Good thing im still in my planning stages of this whole project

 

[bronchole]

Sorry for that, but better now than later.

 

[FROADER]

Sorry for that, but better now than later.

maybe I should just suck it up and spend the extra $$ and do a Y link. This might narrow me down to using a tj 44, dana 30s don't like 35 inch tires.

If that's the case, check out Jefe's build thread.

http://www.explorerforum.com/forums/showthread.php?t=73370

Here is a 2nd gen v8 build with leaf springs.

http://www.explorerforum.com/forums/showthread.php?t=247517&highlight=section525

If you find the right set, leaf springs can be great! Just do some more research before you completely change your mind. Just don't use that rear d44.

 

[ShinySquirrelXLS]

Here is a 2nd gen v8 build with leaf springs.

http://www.explorerforum.com/forums/showthread.php?t=247517&highlight=section525

If you find the right set, leaf springs can be great! Just do some more research before you completely change your mind. Just don't use that rear d44.

I've been doing some more research. Section525's build has definitely gotten back on track and im going to stick to my guns and do leaf springs with a waggy front 44. I found a link on his thread, i was able to see his rig in action. That is what mostly made me go back to the leafs. I also figured that leafs would better for the type of wheeling that i do around here in jersey. We have alot more trail riding with little obstacles. Nothing extreme with big boulders where coils springs would be more effective.

My hood lift supports came in. Im looking to install them this weekend.

 

[ShinySquirrelXLS]

definitely staying tune for this! whens the official start date?

My plan is to build the axles over the winter, and to do the fab work in the spring.

 

[ShinySquirrelXLS]

First fix on the Merc. Hood Lift Supports.

Time to tackle an easy fix for the Red Dragon. I bought these Monroe lift supports for my explorer 2 years ago and they seem to be holding up well, so I figured I would get the same ones. All fixed

Monroe Part Number 901340

 

[ShinySquirrelXLS]

Keypad fix

My security key pad was looking a little used. The buttons were worn down. I didn't like this too much. I went to the junk yard and pulled a newer keypad out of a 1999 xlt exsploder. I found one that looked practically brand new.

Pulled out the old one and found that someone had lost the metal security clip and they had hot glued it back on the door.

Went back in perfect. Keypad lights up. All the buttons work.

 

[ShinySquirrelXLS]

Front Bumper

My uncle works at a junk yard and is always find something cool to bring home. Well a few days ago he tells me that some kind of suv came in with an off-road looking bumper. I told him to bring it home. Im expecting it to be like a little safari bar or something cheesy. So the following day he brings this home!
Than he tells me that it came off of a 2000 explorer sport. This couldn't have been more perfect!

Best part is i got it for free!
It just needs some sort of winch plate incorporated with it.