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1992 explorer gets a solid axle and v8 5 speed

My Duff radius arms have held up very well over the last 12 years. I almost went with the Duff solid axle swap kit for Rangers and Explorers, but I wanted to push the axle 2" forward so 35-37's would clear the firewall.
We're going for 37s with the duff kit. Will it not clear with trimming and proper lift height from your experience?
 



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When there is a will there is a way
Just because it’s a “kit”
Doesn’t mean we can’t push it forward a bit

Interested so see what @BKennedy says about this :)

After that it’s wheel selection and bfh for tire clearances. I have the 37s here with me already so that really helps :)

Should be getting to the sas setup by this weekend if all goes well
 












If I remember correctly, I called Duff about their kit. The way the frame track bar mount uses the cross member and the bottom of the coil bucket you can't push it forward. You are better off buying a generic weld in track bar mount. Set the axle where you want it, install the track bar to the axle side and weld the frame side mount where it needs to go. If you use a weld in frame mount, you can also get the track bar and drag link the same length, something I should have done but didn't know better. My track bar is about 1.5" shorter than the drag link.

This picture is off Duff's website
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I used an adjustable length bar from BC Broncos. Got their rod end steering kit to match. I've had to replace the tie rod but that was my fault. The saddle type tie rod to drag link mount causes a very small dead spot in the steering because of tie rod roll. Rod ends wear quickly in steering links. I've gone through at least four sets.

If I was going to do it over, I would get a one-ton TRE Y-link tie rod over knuckle steering kit from RuffStuff.

The track bar from BC Broncos has worked out very well. It has a rod end at the frame and uses plain old Ford bushings at the axle end. Keeps felt road vibrations down but still allows lots of movement. It's threaded several inches on the frame side so it can be cut down to fit.

The Duff kit doesn't address the single sheer axle track bar mount. I ended up double-shearing the axle mount after I used the Duff kit to raise it. Fabbing the mount out of 1/4" plate would have been easier. To get the track bar on the same plane as the drag link, you have to make adjustments to the mounts that the Duff kit doesn't have.

The coil buckets should be spaced out so the coils sit vertical. The early Bronco axle is about 3" wider than the frame rails if I remember correctly, which makes it near perfect for a swap, but nothing lines up.

The Duff radius arms retain the on-highway stability of a RA, but their length allows lots of articulation. I started out with 4* bushings but ended up using 7* ones to get the caster right. I have no idea how much lift I have.

Using a high pinyon D44 and radius arms means you can't point the pinyon shaft at the transfer case output. I used a double cardin front shaft, which I know is wrong but it allows more movement and less strain on the U-joints. With the Atlas II the shaft is very short.

I also ended up cutting out most of the crossmember and making a bolt in replacement. You can see it in the pics below. You have to hack it up to clear the HP D44. Having a bolt in one, makes accessing the bottom of the engine way easier and might save you from any oil pan clearance issues with the V8 swap.

Most of the issues I wrote about don't matter in the dirt, but do matter on the pavement.

Couple pics of my well used dirty suspension.
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Yes thanks for the info!
I have planned to do much cad fabrication for this sas as I knew a kit leaves lots to be desired

You can’t change the pinion angle more by using degree bushings at the cast wedges?
 






Yes thanks for the info!
I have planned to do much cad fabrication for this sas as I knew a kit leaves lots to be desired

You can’t change the pinion angle more by using degree bushings at the cast wedges?
You use degree bushings to adjust caster. With a lift, the degree bushings actually turn the pinyon down while increasing caster. The bigger the lift and tires, the more caster you need to get it to drive right. If you wanted to change the pinyon angle you would have to relocate the wedgies, then cut and turn the inner C's to correct for caster. If you only lock the hubs when crawling pinyon angle isn't a big deal on a front axle. Will also save a lot of fuel doing it that way.

I clearanced the heck out of the joints in my front driveshaft and used a high angle output on the transfer case to keep it from binding. I have a lot more suspension travel and a taller lift than I think is planned for this build.
 






I unlock my hubs for highway use I’m sure most sas and big lifted ttb trucks would be this way

Thanks for the explaining about the caster Helps a lot
So how close are 37s to clearing on your rig?

Would be about 1 more inch into your firewall at full stuff based on your 35x12.5 on 15x8.5 wheels

We will be running hubs and a double cardan front shaft from 4406 t case
 






I moved the front axle forward about 1.5". I still had to pound the pinch seam flat on the firewall because it cut up my tires. I was advised by the SAS gurus that it needed to be at least that far forward. I had to trim the back of the front fender a lot, and the front of the fender a little. I also rolled the edge of the rear tire well so it wouldn't rub, but my real axle is 2" wider due to the C-clip eliminator kit. I'm running that same size tire and wheel.

When I had custom leaf springs made, it raised my vehicle height about 2" from when I did all the trimming. It should clear 37's now, but they are double the cost of 35's when you factor in having to buy 17" wheels. It's not worth the cost to gain 1" of ground clearance.

If that Explorer hasn't had the rear disc brake conversion, I would add that to the list. It's fairly straightforward, especially for someone as experienced as you. It made a big difference in braking power, and I have a severe dislike of drum brakes.

The best tutorial was done by the late great T-bars. Miss you buddy

The only thing I would add is a adjustable proportioning valve for the rear brake line.
 






Or run a 95 no frills master cylinder
Thanks!! We will be clearing these 37s one way or the other
I plan to push it forward 1.5” as that is still good with the steering gearbox my research shows.
My favorite sas swaps from
Over the years have been jefe or the old grape ape ranger (d60)
This gen 1 is going to be more like your setup or Kirby’s I have the help of a good friend of mine here in Idaho who is a suspension master and had a full metal fab shop
Just miles from here and he owes me some favors :) I will be enlisting his help to make sure I get this all 110% perfecto
 






Progress

I put a jack under the transfer case and support it. Remove rear d shaft and finished cutting the exhaust
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With the crossmember out I lower the jack and all 5ea 13mm t case bolts easily accessible

Old junk yard trick for getting the stubborn 8mm 12 point front d shaft to t case bolts… lightly tap the wrench with hammer… they will come loose

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Crossmember was freed from rock rail and frame with two cuts

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Bellhousing bolts so easy to get now, 20v dewalt impact with 36” extension.
I use a ratchet strap to make a cradle for front of the trans and a floor jack at the back. This way one guy can lift the Mazda over the y pipe and carefully lower it to terra firma

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Interior had to drop the switch console, to gain access to shift boot, inner boot and finally 3ea torx screws for shifter

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Modified exhaust

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I can tell this trans has been out before, the 02 sensor wire holder bracket was not on its bolt

not surprised since 1992 was 33 years ago
Has a newish starter

Shortly after all that trans on the ground

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Clutch still has plenty of material on the driven disc

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Slave cylinder no signs of leaks

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Shift rail plugs just barely leaking =
Low mile m5od or replaced previously

Truck then lowered to the ground
Engine Mount nuts removed
One more bolt and engine is out
There is a bolt on passenger side engine mount that holds the starter wiring harness… I’ve been bit by that enough times to know better then to lift the engine without removing it first

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Jack under back of the engine to keep intake off firewall while I setup hoist

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Transmission is newer and the truck itself is a low miles example (116K if I remember correctly). My grandma replaced it after money shifting into reverse on the highway about 10 years ago. Starter is 2-3 years old. Converted to R134 2 years ago as well so blows cold instead of the old R12 that was in there.
 






It has 6 gears and Grandma used them all on the highway.
 






Yep! I saw the r134 conversion
When I learned it was a 92 I realized it was a 6 place odo
Then I looked at the rubber pedal covers and overall condition of the truck and realize it’s 116k miles not 216 for sure



I’m am compiling a List of the next round of parts to order

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116,000 / 33 =3,515.152- year!!! Low
Miles
Explains why she runs so well

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115,886 st time of conversion
 






Your 1992 transfer case looks a whole lot like the one out of my 4dr red 4x4 1991 behind the A4LD. I might add a pic later after I can go to the shed and take one.
I'll back track and plug it in here. It is the t-case that I'm proposing installing behind a 5.0/C-5 conversion.
 






This is a bw 1354 e shift t case 91-94 explorer very common t case and tough!!
 






She gave it up
Now to prep for a v8 and rip the suspension out

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There are 3ea 4.0 ohv in this pic and one junk 3.0 block. I need to crush the 3.0 engine so I can put this baby on the stand

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Just ordered a bunch of parts
New 92 4.0 explorer engine mounts
New 2001 f150 4.2 luk clutch
92 explorer luk clutch hydraulics
New acdelco 4.2 starter
I have a 4.2 flywheel here so I will have it surfaced in town
These are the parts I need so I can put the 302 and m5od-r2 into the truck
The 5.0 engine is going on a stand and getting soft rebuild ;)
 






Big nasty cam :)
 






You already know which comp cam is going in this baby

All power washed degreased and ready for new life

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Join the Elite Explorers for $20 each year or try it out for $5 a month.

Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
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Krylon spray paint is my favorite brand by far… short of buying Vice Grip Garage rebuild black lol

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Just ordered canton billet oil filter remote
Mount adapter (Amazon) and a melling dual sump oil pan and pickup for a 84 mustang 302 (rockauto)



This 302 engine is getting a rebuild kit, new bearings and rings will hone the cylinder walls and give it a full refresh… all new gaskets and wear parts

Now I get to put her way in the air and remove the entire front and rear suspension

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The nice part about this canton racing adapter is you can rotate the hoses to point any direction you want and then lock down the center bolt. It clears the steering gear box by about 1/4”
I already have the remote oil filter mount itself

The dual sump oil pan for a 84 mustang 302 clears the ttb engine cradle

Once all these parts get here and I rebuild the engine we can drop the 302 and trans in
I should have a good idea of the axle placement by then as well

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