034x4's D44 SAS thread... | Page 15 | Ford Explorer Forums - Serious Explorations

  • Register Today It's free!

034x4's D44 SAS thread...

I think this is my first post here, but i've used this board for alot of research on explorer and ranger SAS. So i finally decided i should post my project and it's progress so far.

The truck originally is a 2003 edge 4x4. 37,000 miles with 4.10's/LS.
I had 3" body lift, fiberglass front fenders and cut rear fenders to have plenty of clearance for 35x12.50 BFG mudders. Made a trip down to savannah and on the way home my passenger hub bearing pretty much exploded. Taking with it, the pass knuckle, caliper, rotor, bent inner tie-rod, ground flat outter tie-rod. I already had the D44 in preperation for the SAS but with this, i decided to go ahead and start on it.

This is the ranger, in the beginning.

7cbc01ed.jpg


After the bearing failure, at 70mph on I-75 north...

2a08b95d.jpg


33975f5e.jpg
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





034x4 said:
Don't remember who, but there is a guy on pirate that says if you can find documented evidence in ANY state that beadlocks are indeed, illegal, he will pay ~50$ i think.
EXACTLY...
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





JS91X said:
did you have to get 2 highsteer arms or just one from btf casue i only found 1 for a d44 (the passenger arm) from btf, and whered you get your knuckles? and whered you get the front spring pads ?

seek and ye shall find.(parts mike knuckles and arms) he has spring pads too.

I want to see your range in action 034x4 hurry up so i can decide on leafs or coilovers!!!
oh how does the frame flex now without reinforcement?
 






JS91X said:
did you have to get 2 highsteer arms or just one from btf casue i only found 1 for a d44 (the passenger arm) from btf, and whered you get your knuckles? and whered you get the front spring pads ?

Short bed. 2 high steer arms, one for each side. I ordered them online so I know they're there.

The knuckles are Parts Mike Parts d44 flat-top knuckles.

Front spring plates are TT's fabworks wagoneer spring-over spring plates with u-bolts. www.ttsfab.com i think is the site.
 






nappahdog said:
seek and ye shall find.(parts mike knuckles and arms) he has spring pads too.

I want to see your range in action 034x4 hurry up so i can decide on leafs or coilovers!!!
oh how does the frame flex now without reinforcement?

False. Parts mike knuckles. Blue torch arms. TT fabworks perches.

The frame doesn't flex any noticeable amount.

Thats a huge gap, leafs or coilovers. I picked leafs for simplicity and price.
 






i picked leafs for the same reasons

who said leafs don't flex?

f58517a9.jpg
 












2.0 fox coilovers are about the same $ as alcans and a good shock I've been researching for a while. heims are more but??....those were just assumptions about P.M.,why did you bounce around when you can get it all in one place?
price?
hey yomie, who did your SAS? did'nt he say coilovers would be easier or am I making another assumption?
 












nappahdog said:
2.0 fox coilovers are about the same $ as alcans and a good shock I've been researching for a while. heims are more but??....those were just assumptions about P.M.,why did you bounce around when you can get it all in one place?
price?
hey yomie, who did your SAS? did'nt he say coilovers would be easier or am I making another assumption?

No i was agreeing with 03 saying i went leafs because of price and simplicity. IMO Leafs would be easier..

I did my SAS myself.

J...that wasn't funny :fire:
 






I can't believe you guys didn't even invite me to ride along when you went to Tellico. :p
 






i may have missed this, or it may not have come up, but what are you doing to prevent axle wrap in the rear? and is axle wrap ever a problem on leaf sprung fronts?
 






Axle wrap can be a problem on the front, especially with soft leaves. Anti-wrap perches and traction bars help.
 






Axle wrap won't be a problem on the front I don't think. I have TT's fabworks perches, and they are long as hell. So they should distribute the load enough to help prevent alot of axle wrap.

The rear springs are 63" long. I don't get hardly any axle wrap on the street. But we'll see when I can get it in low range on the trail. I don't wanna run traction bars.

Nappahdog: Leafs and shocks are cheaper than a coiler setup. With coilovers you still have to figure out the link geometry, where the hell to mount them on the frame. You have to worry about deathwobble/trac bars if its not a triangulated 4 link.
 


















I'm keeping the UPS man in shape.

3b2e6c01.jpg


19538e8e.jpg


f177db0f.jpg


18cce102.jpg


Thanks jesse (daytonabeachranger). It was packaged good, took me about 10 minutes to get through all the tape and old t-shirts lol.
 






Ok well i figured since my truck is pretty far along I'd make a post summarizing what all I have done and all of the specs of the build. Hope this helps some people so they don't have to read the whole thing.

2003 Ford Ranger Edge 4x4 Black
3" PA body lift.
Cut off IFS and all related bracketry.
1981 Jeep Wagoneer Spring under Dana 44.

Internal parts of Dana 44
Yukon 5.13 gears.
Yukon Master install kit.
Full spool.
Yukon Chromoly 30 spline inner shafts.
Yukon Chromoly 19 spline outter shafts.
All brand new brake parts (rotor, calipers, bearings etc)

External Front axle parts/set up
Parks Mike Parts Flat top Knuckles w/ ball joints and high steer arm studs.
Blue torch fab High steer arms (both sides)
TT's fabworks Spring perches and u-bolts.
Blue torch fab Kryptonite diff cover and bolts.
1.5" .250 wall Tie-rod/drag link with 5/8" heims.
RE1555 28" stainless steel brake lines.

Steering
1992 IFS toyota steering box from Foxfab.
Ported for hydro assist by Mild2Wild.
PSC hydo-assist ram.
Custom steering shaft (ranger and 'yota shaft mated together)
Allprofab one peice pitman arm.
Custom power steering pressure hoses.

Front suspension
Alcan custom leafs based off of 8 3/8" rise 7 leaf waggy springs, shortened ~6".
4.5" Stock ranger rear shackles.
No shocks as of yet lol.

Rear axle internal
1999 Explorer Sport Trac 31 spline 8.8.
Yukon 5.13 gears.
Yukon master install kit.
Full detroit locker.
Superior chromoly 31 spline, custom 6 lug shafts.

Rear axle external
Redrilled rotors to 6 lug.
Brand new brake parts (rotor, calipers etc)
7.5 Spring perches off of elliott's old axle lol.
95 exploder spring plates.
95 exploder u-bolts.
Stock diff cover and bolts.

Rear suspension
63" 1992 Chevy 1500 leaf springs.
4.5" stock chevy shackles.
Flipped, cut, and box shackle hangers.
Pushed forward ~6" front spring hangers.
24 (i think?) ES3000 shocks
Mild2Wild shock tabs.

Body
Dovetailed truckbed 17" at tailgate.
Added 2 1x1 square tubing bed supports.
Chopped bumper.
(When i get front fenders...)Cut front fenders.

Engine
MAC intake.
Pro-M MAF.
Half-shafted throttle body.
Ground throttle stop.
Motorcraft double platinum plugs.
Gutted last cat.
2 chamber flowmaster with turndown.

Interior
Door handle surround, floor cup holders, and radio bezel matching green satin paint as axles.
Relocated A/C controls to cup-holders.
Mounted CB in-dash.
Gauges changed to red.
Pioneer DEH1500 (??) headunit.
Sony 1200 watt 2 channel amp.
4 gauge Rockford wires/RCA's.
Custom sealed box i built for 2 Alpine type E 10's (don't have them yet though lol)

Exterior
Headlight mod
Blinker mod.
Camo painted grille and whats left of rear bumper.
60 watt PA speaker painted black behind grille.
MM9500 SE winch (not yet mounted.)

I think thats everything.
 






is that a manual 1354 tcase...hows that winch coming along ? heard about a front driveshaft ? is gas mileage bad now ?
 






You don't ask many questions do ya? j/k man.

Manual 1354 case for the doubler.
If my free metal source comes through i'll mount the winch this weekend.
No front driveshaft yet. Need to decide if i want to do the doubler now, which it will be undriveable since i have to take the stock case out, unless someone wants to donate a 1354 case so I can use it to make all the adapters/shafts.

Last tank I got 12.4 mpg. It's ALOT quicker than before with 4.10's and 35's, so I'm getting happy with my right foot.

I've driven about 1,000 miles on it already. No problems since the d-shaft u-joint.
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





That's a 1350, right?
 






Back
Top