2002 Sport Trac SAS finally begins

Dana 44 out of a 1989 Grand Wagoneer.

My plan is to get as little llift as possible as I dont feel like removing my body lift. So I am using the stock Waggy knuckles, spindles, hubs, rotors, calipers, and likely using new waggy steering parts as well and keeping it 6 lug.

I will leave it spring under as to keep the lift minimal, and use 4" lifted springs. Doing it this way will save me from buying high steer knuckles and a high steer setup. Is this best way, maybe not, but it saves me alot money and keeps my lift to around 5".

Now for those who are asking themselves why am I even bothering with this SAS. My reasons are that my Sport Trac goes through UCA and lower ball joints every other month, and I destroy tires in under 8 months. The truck just cannot handle 35's. PLus it will be way stronger than the IFS, and will flex much more than my IFS system.

If anyone has any thoughts/recomendations/concerns, I welcome all the help you can offer.

I hope money does not slow me down, but the cold weather might, either way my goal is to have this done well before Moab.

 

[IZwack]

Yeah dont test the locker on dry pavement

 

[chad551]

So it looks like I have some learning to do, then to drive this offroad. So what do you do when you are on the rocks?? Turn it off and use 2wd to make a climb?

 

[IZwack]

No you'll be fine on the rocks. See when the vehicle is climbing, of course the nose is up in the air at some angle, so that means the front axle has less grip and less stress. What you'll find is you have a greater chance of breaking a front axle shaft / u-joint when the vehicle is nosed forward and you're trying to back up a rock face for example. At that point, most of the weight is on the front axle which means it has the most grip and greater stress.

 

[redranger4.0]

Your axle probably had a very hard life and the axles broke from general stress over the years.

 

[chad551]

I had the axles bead blasted to get all the rust off Looks like I will just have to get some chromoly axles.

 

[Diff Whack Daddy]

Sounds to me like there was a hair line crack or something somewhere and the dry pavement test found it. I lost an outer yoke like this too, but it was a 30 year old axle and u-joint.
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[chad551]

I went and spoke with a driveshaft shop the other day and here is what one of the guys recomended. He said I should get the a new 1410 pinion yoke for the front diff that is made for the bigger u-joint and this allow more flex and prevent binding. Anyone do this? Also who can recomend some new axles?

 

[lifeguard379]

mine is just my stock drive shaft, and it works great.

 

[IZwack]

Yeah u don't need 1410s - I ran 1310s with no prob. And you will break axle shafts long before driveshat joints cauz the axle shafts are subjected to forces with a multiplier magnitude equal to the gear ratio.
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[IZwack]

Oh and as for the chromo shafts, call CompleteOffroad - that's where I got the chromo outers from for the D60
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[chad551]

Thanks again everyone...

I was afraid this driveshaft was going to cost me $500, to modify my already expensive double cardan superlift shaft..

 

[RockRanger]

If the u joints bind you can also change out the lower part of the driveshaft ( atleast on my 93) I went to dana's website and looked up the one I had. Then I went through the list and found one 2" longer and that gave me more angle. Called up the driveshaft shop and $50 later I had the parts to lenghthen my front shaft and get me 5 degrees more angle.

 

[crazyflights]

Can u show some close up pics of the steering box mounted, inside and outside of the frame? I have a feeling I will be doing very similar steering box swap soon. Thanx

 

[crazyflights]

Also, I looked back thru thread and saw pics of Stic-o's, im just curious how it went , since u have SOHC engine.

 

[chad551]

I will get some pics for you. I have to fix my steering shaft today so it will be a good time to do it. This was by FAR the BIGGEST PITA for my SAS.

 

[chad551]

Did some work on the front end this weekend. I finally got my tracbar installed and wow, what a difference that made. Handling is greatly improved now. I could actually feel the frontend shift somewhat when taking a turn at medium to high speeds. Now there is nothing but a smooth ride

Still need to get new axles though, and trying to hide a 600.00 purchase from my wife is rather hard

 

[lifeguard379]

still no pics?

 

[chad551]

I will take some more pics..

 

[crazyflights]

I no longer need the steering box pics, i saw the other ones in file, but would like to see current pics, since you live in St. Louis, your only hr from Union, MO. you should go to Union fair July 10th that evening at 6:30 is MMOR mud race, will be running my red ranger there, they do have cyl class and should be fast track pit so don't get to mudy, u could run you Sport Trac or just come watch.

 

[chad551]

What time do I need to be there by? I will show up either way to watch or maybe join in the fun.