2001 XLT D44-SAS

[DasFrem]

Who's doin' your gears?

 

[cdsl227]

I'm considering taking a shot at the front myself- but that's up for debate...mmmm...I'm still thinking that one through.

If I send it out- it'll give me more time to fab the rear bumper I'm working on- I'm trying to build something similar to the front.

Didn't you pass on info for a decent shop in PA???

My other thought between- flip-flopping between stepping up to the plate or passing it to someone else was to give that shop a go.

Although I'm not particularly fond of driving out to PA, but then if I drive out- drop the axle, by the time they get that done- I'll have the parts for the rear, so I drive out early- have them do the rear and load the completed axle up and I'm on my way.

You see- I'm still trying to convince myself!

But then again- my other arguement to myself is that it'd be a learning experience...probably a painful one!

Ahhh, what the hell I'll order a coupla extra crush sleeves and have at it!!!

I should get some Thorazine- cause I don't know what the hell I wanna do with it yet!!

One things for sure- I'm not touching the rear so that'll definitely go to the shop you mentioned.

 

[DasFrem]

Yeah, the shop I had mentioned was Up and Over innovations, you can find them at http://www.upnover.com

 

[cdsl227]

Ok, quick little update.

I cut down the leaf to make the Buggy Springs.

I settled at 18 inches for now and if they have to lose another inch or two I'll hit'em with the RotoZip again.

I didn't get to visually fit them yet that's why I settled at 18". I figured no way they'd be any longer than that.

Couldn't drill the holes because I need to take a good look and decide on the mounts first AND see where they fit underneath.

But I went shopping today!

First the Buggy Springs-

And my new toy-

 

[cdsl227]

brief update...

Ok I got the steel together that I'll be using to fabricate the suspension...and a bumper I'm fabricating.

First two are the channels for the Buggy Springs...I'll probably cut them down a little...to be a closer fit.

Spare steel for mounts, etc...

The first piece is (angle) 3/8", that's a little thick, but I'm considering it for the front spring hangers and the bracket to hold the buggy leaf channels.

Some flat 3/8"...

The 3x3x1/4" Box Tube I'll be using for the front crossmember and front spring hangers.

The Front D-44 Parts-

The ARB Locker...

The Master Overhaul...

The 4.56 Gear Set...

That's about it for now...

 

[NOTAJP]

Looking great. I think 3/8" is just right. Keep up the good work.

 

[wes8517]

any updates on this swap? im interested in doing the same to my project vehicle

wes

 

[cdsl227]

I'm just starting to rebuild the axle...it's slow going, but it'll be coming around shortly...


Edit:
Scratch that, I found out they're the exact same universal for the Bronco and the Jeep...one more part down...

 

[cdsl227]

Quick question for anybody that wants to drop an opinion-

I'm trying to get this axle built this week (heh, yeah right).

I've got the Waggy axle completely stripped down and most of the puke cleaned out...I just want to get it a little cleaner.

Question is- in the open end of the axle tubes- I'm kinda tempted to run a sponge with some POR-15 on it down the tube...they're already amazingly clean with a hint of dust-rust (if you could call it that). I figure since the POR-15 bonds to the metal perhaps it'd be a fair idea to run it up the tube.

I know it's not needed and the tube'll take forever to rot, but...I figure it'd be better than coating it with something oil based that would hold dust.

POR-15 it or leave it bare?

 

[DasFrem]

Leave it, don't touch the inside of the tubes what-so-ever. As per the axle housing on the outside, if you got some POR-15 laying around, go for it, nothing works better, although I think it's a bit overkill and just use some enamal rattle can myslef.

 

[cdsl227]

I've got about 3/4 gallon of POR-15 leftover from the bumper.

I planned on using it to do the entire undercarriage after the SAS, but I figured I could get enough out of it for the axle also...

Thanks!

 

[cdsl227]

Ok, I'm kinda curious about one thing though...I've seen on some rebuilds on the net- they paint the axle shafts just up to the point where the seal would contact the shaft...I mean I've got my inner shafts out and they look like they could use a quick run over with a wire wheel, but they're solid.

Would a little paint on the areas that don't come in contact with seals be a problem there...I understand they don't do it on OEM parts, but then they design them to fail from any of a thousand causes over their lifespan.

The seals only sit at the inner end of the tube (pumpkin)...so the tube itself can take on water if submerged...wouldn't a little POR-15 do it some justice in that case?

Or is it that the heat generated by the pumpkin can cause the paint to peel or flake inside the tube?

What'dya think?

Thanks!

 

[RFR2212]

You gonna pin them buggy springs? I personally wouldn't run them on a street vehicle up front, but would pin em and allow them to be limited....

 

[cdsl227]

They're definitely going to be locked for the street, no movement at all...

I'm still curious about putting some POR-15 on the axles though...I've seen painted axles and I can see where it would limited rusting of the axles, but then I can also see that it could possibly put them out of balance and cause vibration, but then hey- rust buildup would too? Right?

 

[Rx4phun]

If it is a thin layer I dont think it wouel hurt anything, you arent going to makeit off balance with only a blittle bit of it just dont go to heavy and it iwll protect it. I like coating stuff like that so i would probably do it
Gary

 

[cdsl227]

Quick update...I haven't gotten far, but I have a feeling the axle rebuild is going to start moving.

My girlfriend bought me a coupla toys for Christmas, well actually my birthday.


a few pics...

Toys first...

Now the axle...

That axle is a far cry from what it looked like when I first got it!

 

[Hotweels]

ahhhh nice and bling bling..... too bad you will end up burnin off some of that shiney POR-15 when you weld the new spring pad's on
keep workin on it man...

 

[cdsl227]

I know, but I have plenty more for another quick coat when I done.

Took my first read of the backlash today with no carrier bearing preload...it's only off by 0.003 so once I get the backlash a little tighter than it should be I'll check the pattern and start working on the preload...so I can modify the bearing cap for the ARB air inlet.

Since I had to buy all these tools to do this axle I think I'm just gonna do the rear myself.

 

[cdsl227]

Ok, a coupla pictures of the gear pattern...what'dya think??? They show the coast and drive side pattern...

And some pics of the carrier bearing cap I had to modify for the ARB...

Looks good to me...

I'm just a little concerned about the backlash...it's stange but when I rotate the diffy- it has about the same backlash all the way around...but there's one spot where there's like no backlash space. Weird. Any thoughts??? How about the pattern- from what I've read, and I've read quite a bit...it's a trade off and almost impossible to get it perfect.

The backlash is a little tighter than it should be, but I still have to add some more carrier bearing preload...just a little because I'm almost dead on with the preload...

I'm hoping the little I add will give me 0.001 or 0.002 more on the backlash...if not. Time for the press again.

 

[V8BoatBuilder]

I can't make a comment on the gears, might be worth starting a new thread on just the gears - you'll get more people checking that.

Just a random question on the SAS: what are you doing for the t-case? Doesn't make too much sense to leave the AWD 4404...