2000 Mountaineer Expedition Build FW D44/9" SAS

My DD has turned into a project vehicle. I am building it up to be a capable overland/expedition rig for long range trips to include camping and all around adventuring. We have a few trips tentatively planned already. I just need to get this thing going as we have much that we want to see.
I will be making a roof rack to carry a few items, but most will be carried in a trailer, so to keep from putting too much weight up top. Also, it will be nice to have the roof top tent set up on top of the trailer, so I can unhook and leave the "base camp" in place and go wheeling.

Here is what I have so far:

2000 Mercury Mountaineer 5.0
BW4406
Black Rock 942 16x8 steel wheels
255/85/16 BFG KM2s load range E

Still needed:
Rear bumper, spare tire/fuel carrier
Winch
Roof rack
Trailer (have plans made up, but have other priorities)
and a lot more stuff...

Well, thats it. Stay tuned for updates.

 

[nobodyspecial]

Oh, and I also got the links fixed for most of the other pictures in this thread.

 

[nobodyspecial]

Has anybody had any luck reusing the steering box from the Bronco of F150 they got their axles from? Am I going to have to find a first gen explorer box?

 

[turboexplorer]

I used a 1995 F-150 steering box. Love it. From what I have found it has a steeper ratio than the first gen X boxes. On my truck I can go from center to full lock in 1 direction with 1 3/4 turns is all. Feels great on the freeway and my 5.0L PS pump boosts it great. Super easy to turn even twisted out on rocks with 37" tires.

 

[nobodyspecial]

Hmm... Interesting. I will have to search and find if the newer F150 pumps are set up the same as the old ones. I just don't know what they look like off the top of my head.

 

[nobodyspecial]

So, I have been reading that Toyota IFS boxes work well. Are there other good options besides the explorer or F150 box? I would prefer to keep it all Ford.

If not, it sounds like the newer F150 box might be the way to go.

Also, who here has done disc conversions on their 9"? I am looking at a few different set ups, but would like to hear some personal experience.

Oh, and does anyone have any preferred rebuild kit brands for the 9" and D44? what is your preferred bearing?

 

[turboexplorer]

Problem with the Toyota boxes are they mount on the outside of the frame. This means your intermediate shaft has to cross over the frame so adds unneeded angles on that shaft. And on my specific build it wouldn't have worked since where it would have to be is where my trac bar mount is. I feel there would have been some interference issues there. Also personal preference but fun to keep it all Ford.

9" brakes there should be tons and tons of kits to convert them.

And I run Timken bearings all the way. Never had any issues for failing or fitment. And it's OEM for almost all Ford stuff.

 

[MattysTA00]

Nice..

 

[WormsExplorer]

Just wondering if anything new on this build?