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91 Explorer on Dana 60's

Finally finished my long running Dana 60 axle swap.

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Build threads:
Explorer Forum
Demon4x4
Pirate4x4
Texas4x4

Non SAS build threads:
EF Dana 44 Solid Axle Swap Project Thread
EF 700r4/Atlas Thread
Demon4x4 Dana 44 Install Thread
Demon4x4 700r4/Atlas Install Thread

This is my second attempt at a SAS, the first being a narrowed high pinion Dana 44 from a 1979 Ford Bronco.
You can see that registry thread here.

The specs for this SAS:

Front Axle:
1979 Ford high pinion Dana 60
Summit Machine custom engraved flange covers and 35 spline drive slugs
Warn 35 spline outer stub shafts
Ford Sno-Fighter inner axle shafts
Detroit SofLocker
5.13 gears
1350 U-joint yoke
Stage 8 Dana 60 Spindle Locks
Longfield spindle bushings
Lug studs converted to 9/16-18" to match rear

Rear Axle:
1979 Ford low pinion full float Dana 60
Detroit SofLocker
5.13 gears
Crane High Clearance Dana 60 chromoly differential cover
1/2 ton Chevy disk brake conversion
1350 U-joint yoke

Front suspension:
14" 2.0 Racerunner dual rate coilovers, 250/350
Custom 4 link & coilover hoops
Lower links are 2.125 x .375" wall DOM
Upper links are 2" Summit Machine aluminum links
All heims are 1.25" Ballistic Forged Rod ends & RuffStuff jam nuts

Rear suspension:
Stock 4-door Explorer leaf springs
2" Rancho Add-a-leaf
Warrior 153 Shackles
Ballistic Fabrication SOA kit
Rancho RS9112 shocks

Steering:
Artec Industries Full hydro mount Dana 60 truss
Reid Racing Ford Dana 60 steering knuckles
Artec Industries Ultimate High Steer Arms
Reid Racing Bronze upper kingpin bushings
ARP high steer and spindle studs
PSC 8" double ended hydraulic steering ram
PSC Saginaw style steering pump, reservoir and power steering cooler
CE120 orbital valve

Other misc goodies:
2002 Dodge 2500 Master cylinder
Misc brackets from both Artec Industries and Ballistic Fabrication
Custom engine crossmember

Tires & Wheels
16.5x9.75 H1 double beadlocks, recentered to 3.5" backspacing
HDPE runflats
Ballistic Fabrication Rock Rings
37x12.50x16.5 Military Goodyear Wrangler MTS

I'm sure I'm forgetting something.

More pics:
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OffTrac

Elite Explorer
Joined
February 22, 2010
Messages
3,770
Reaction score
9
City, State
Dublin, GA
Year, Model & Trim Level
'01 Sport Trac 4x4
Awesome build!

Thank you for the details in your build threads and part numbers. I'm sitting on a '79 Sno-Fighter and D70 in the garage. This certainly helped my growing shopping list.
 








obie

Well-Known Member
Joined
June 13, 2012
Messages
904
Reaction score
9
City, State
Northwest Indiana
Year, Model & Trim Level
2003 Sport Trac 4x4
Before I saw who posted the thread, my first though was 60 inch wheels, haha.
 








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