99 Explorer SAS D30 | Page 3 | Ford Explorer Forums - Serious Explorations

  • Register Today It's free!

99 Explorer SAS D30

Well I'm taking an early night off tonight from my SAS on my 99 explorer so I figure I'll start my write up on it...
My ride is a Cheery 99 Ex XLT leather interior all the bells and whistles

First off I'm doing a D30 for a few reasons...
1- Wanting to keep the ABS
2- Stock(ish) width
3- Wheel bolt pattern same
4- CHEEPER...


I know, "why not just do a 44 and get it done. Your gona wheel the thing"
Well Ya I'm gona wheel it but not that hard besides I like breaking stuff...lol...

Out back it's getting SOA, AAL, and a lincoln locker...
Gears will be (eventually) 4.56 or 4.10's will deside when the tires are bought, which will be desided on when the lift is in and I see what will look best 33's or 35's???
Springs are originally out of a YJ but thanks to Mike at Abby spring they are not stock;)
Steering is the box out of my old 91 Ex
Front drive shaft will be built at Abby spring (thanks again Mike)
All the work is being done by me with help from My good buddy Pete at Pete's little shop;) (Man I love plazma cutters and Hoists) Keep in mind that the shop is not a pro auto shop but rather a back yard shop. My buddy is a computor geek and I'm a licenced auto tech for 20+ years 12 of those with Ford
T case will be out of a 96 ranger electric shift (and yes you can control it with the 99 system if you have the neutral tow option installed) I know WHY???

Pix's will follow soon (I'm taking lots)

Monday Dec 3
Did some running around and gathered some more parts. Fabbed up the front spring hanger coppying Section's design but using 2x6 3/16 steel (little lighter and plenty strong... Springs dropped off at Abby Spring. Measured up stock hights of my Ex (damn I left the #'s at Petes I'll post later). Called the dude with the D30 "Oh man it's snowing and the powers out can't get it out, call me tomorrow." Mounted the spring hanger/front cross member Put the bumper back on and calles it a night.
10 am to 9 pm

Tuesday Dec 4
More running around picked up the springs and u bolts. Called the dude with the D30 again "Oh ya I'll be at the shop later call me in the afternoon" Fab up the front shackles. Calles Dude back, now the axle I was trying to get was a D30 out of a 95 ZJ with the better steering nuckles and all. "Ya man that D30 out of the 88 XJ is out and ready for you." Um no we agreed on an axle out of a 95 ZJ I need the ABS! "Oh my boss dosn't want to part that one out yet."
Ok plan "B" get a line on one out of a 96 XJ with ABS, but a 2 hr drive away Oh well,
Back to the shop I go and start cutting. Man that first cut is a killer on a very cherry 99 Ex, but I'm either crazy or stupid cuz I think it's fun...lol...
Man I love Plazma cutters and hoists
Long day 9 am to 1 am

Wed Dec 5
Run around getting Insurance on my pimp ride 2000 Malibu so I don't have to thumb around (it's 1/2 hr drive to Petes from my place) Head out to pick up the D30 Sweet shape came with front drive shaft and purdy new brakes $100 Sweet deal...
Back to shop and did a bit mor plazma cutting and grinding bit of painting.
Called it quits early looking after the kids tonight while the wife had an epicure party (oh joy)
10 am to 4:30 pm

Tomorrow we will see I'll post more later...

Cost list:
D30 $100
Braded flex lines $30 for the 3 of them new (sweet score)
Steel $100
T-case -$450 (sold a dude my 91 case and installed it he gave me his 96 ranger case, he needed a cable speedo auto shift case I didn't)
Springs and U-bolts, (worked at Abby spring for a year and Mike is a great guy) $30
Gear oil and brake fluid Free (don't ask)...
Paint, primer, grinding disk's $25
48 Kokanee's $*&^ (price restricted by Canadian Government)...lol...:can:

So far I'm still in the red Cool

*Side note My 2000 Malibu is for sale if any one is interested This will be my Gear and tire money $4500 OBO*

Did I mention I want this driving by next Monday...lol...

Cheers Randy...
:exp::salute::thumbsup::can::bdrunk::ttiwwp:
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





I know its an old thread, but i was wondering, if i dont have the money right now but i have a dana 30 sitting around, is it possible to swap the solid axle in with a spring under axle setup and not lift it to much.... just a thought
Thanks
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





Wait till you can do it right... Keep saving up the parts and stuff till you can afford to do it all...
Way safer and prolly cheeper than doing it 2 or 3 times...
 






I have a '00 XLT and I'm really thinking about doing this, hopefully not too long in the future. Just don't have the money right now :rolleyes: I already have a 3" BL and shackles and 32x11.5x15 BFG All terrains. just want to go a little bigger ;):D But I do a good amount of freeway driving do you have any problems at higher speeds? say like oh 65+ or so? I like the way you went with the D30 to keep close to the same width as stock.
 






I have no real problems at all with it... I drive it to work every once in a while (when my students bug me enough...lol...) 100 km's each way at 120kms on the freeway... getting a little noise from the front bearings so I'll do them in the near future...
I have gone faster but I hate tickets so I tend to keep it within 10%...lol...
The 30 is plenty strong enough for what I do with it and hell it's the way I think Ford should have made it...


Cheers Randy...
 






I couldn't agree more that our 2nd gens should have had a straight axel. What other kind of springs would be good to get for the front since i dont have the kind of access you do to a spring shop. and also, front and rear drive drive shafts?
 






Jeep Wagoneer springs will work for you. I changed the t-case to a manual shift out of a 92 explorer. You can have that one modified to work. Rear was ok...
 






Some newer pix's (poser shots...lol...)
 

Attachments

  • pix #2.jpg
    pix #2.jpg
    150.5 KB · Views: 2,191
  • pixX3.jpg
    pixX3.jpg
    123.7 KB · Views: 2,260






dang I really want to do an SAS haha. what would you recommend to avoid axle breakages with a D30?
 












They are strong enough for 35's just don't drive like an ass hat...
 






Well it's been a while since I posted on here...
I sold the 99 :( I just wasn't using it and my driveway is too small...
The young dude I sold it to is loving it last I heard...


The good news is I just picked up a 93 for far too cheap to pass up....Here we go again...lol...This one is in great shape but it's old enough that I can do some real cool stuff to it...
Pictures and a new posting will follow...

Cheers...
 






How much did you let it go for?? It sure was a nice lookin ride.
 






Got just under $10g for it...
Young kid first vehicle...
Was sad to see it go but at least it will get used and I don't have to scratch the ship out of it...lol...
The new one will probably be a class project for my race program kids...
That will keep them interested in school...
 






That is Canadian $$$$ so like $500 us...lol...
 






I am looking to do the same project on my 95 XLT
What was the reason for the transfer case swap?
are you able to send me some specs on the shackles and the crossmember where the front springs mount to the front of the truck and also the frame?
Truck looks awesome!
 






I am looking to do the same project on my 95 XLT
What was the reason for the transfer case swap?
are you able to send me some specs on the shackles and the crossmember where the front springs mount to the front of the truck and also the frame?
Truck looks awesome!


The 95 is the same as my old 99 so the build can be similar.
The t-case swap was done to get rid of the weak front drive shaft and to put a manual shift case in. I had done the brown wire change on my original but I wasn't happy with the weak front CV style shaft. So I got a t-case out of a 92 (I think it was) Explorer. Made a new x-member and it worked awesome.
If you read back to the start of the posting you can find out more about the front spring mounts and shackles I used / made. There are also a lot of other people on here that did the same set up so do some looking...
Cheers Randy
 






An adapter plate can be machined pretty easily to change that electric shift transfer case to a standard u-joint style front driveshaft.. Or, if my memory serves me, you can change the output shaft on the case to one from an older case with the u-joint driveshaft, making it (front shaft) a bolt on, other than the length.


GB :)
 






Yes that is true but for the price I figured cut the hole in the floor and go standard shift???
 









Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





I know this thread is dated but great info and glad the photos are still attached!
 






Back
Top