• Register Today It's free! This box and some ads will disappear once registered!

^^Searches ExplorerForum.com^^

Bkennedy's SAS and Rebuild Thread



Join the Elite Explorers for $20. Gets rid of the ads!

Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private Conversations, and more. Join Today. Your support is greatly appreciated.






BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
They will send 2 quarts with the case, included with it. They also use Redline synthetic for it besides the AmSoil.
From what I saw, it was not included, but I could purchase a install kit that came with two quarts of fluid, and breather hose. If it shows up with fluid, I guess I will have several years worth on hand.
 
Last edited:


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
I got about half of the ball joint replacement job finished today. Still need to finish up the driver side and do the passenger side, but I got the driver side ball joints replaced. I like the MOOG joints with the side zerk fitting. I purchased a ball joint service kit from Harbor Freight that was on sale. It is working great so far. Also replaced the rear brakes and installed some slotted and dimpled rear rotors to match the front. I have new brake pads for the front axle as well. When I drained the diff fluid, it came out looking like new. I should have kept it and reused the fluid since its been on one Truckhaven weekend and a couple of day trips.

If anyone wants a set of rear rotors for a 99 Explorer, let me know. The are like new.
 
Last edited:


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
I was installing the front wheel hub when I spun the lock washer on the threads. I felt it as soon as I started really cranking on it to torque the outer nut, it felt all wrong. Took about 20 minutes of beating it with a punch to get it to come loose. The tab took out some of the threads and there is no way to clean them up because two rows are missing at the tab slot. The spindles are probably OEM from 1976 and were a little banged up when I got the axle, so I decided to replace both of them. Quick interweb search pulled up Jeff's Bronco Graveyard as having the best deal I could find at $75 each (Spicer). I added the Stage 8 spindle locks (Stage 8 X-LOCK Dana 44,30 Locking Spindle Nut Assembly-Broncograveyard.com) because the pin was bent on the inner nut so I needed to replace them anyway, and I am sick of dealing with the OEM lock nuts. I also added new wheel bearing seals, and knuckle to spindle nuts. (Total = $334 shipped). I thought about just ordering the Stage 8 spindle locks and hoping the lock washer would line up before or after the damaged threads, but the missing threads would always have me wondering when it was going to fail.

I have had the Wild Horses spindle bushings (Extreme Spindle Bushings for use with Dana 30/44 Pair) since I did the SAS, so I ordered another set of them even though the old bushings would probably be alright to install in the new spindles. (Total = $42 shipped). This ball joint job is costing a lot more money and time than planned, but I will have less to worry about next time I am miles from a paved road.

If anyone wants a set of new spindle bearings and seals, they come with the spindles and I will have no use for them.
 


Stic-o

Elite Movie Star
Elite Explorer
Joined
September 1, 2002
Messages
13,791
Reaction score
475
City, State
Lake View Terrace, CA
Year, Model & Trim Level
'91 Navajo '99 XL '16 XLT
If there Dana 44 spindle bearings , Yes please!

Last time I repacked mine I wasn't really happy with the one side ( original ones since I did my SAS), but it was right before a trip....that never happened:(
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
OK. I will throw them in the RV, and if we ever go anywhere again you can have them.
 


Stic-o

Elite Movie Star
Elite Explorer
Joined
September 1, 2002
Messages
13,791
Reaction score
475
City, State
Lake View Terrace, CA
Year, Model & Trim Level
'91 Navajo '99 XL '16 XLT
OK. I will throw them in the RV, and if we ever go anywhere again you can have them.
Ouch, Let's do Big Bear, when do you want to come up? Drove JP down to auto parts store, just to drive it. She's ready to go.
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
I was going to go tent camping up there next week, but now I'm waiting on parts.
 


mounty71

It's green, not gray.
Elite Explorer
Joined
February 3, 2007
Messages
3,597
Reaction score
178
City, State
Oakland, CA
Year, Model & Trim Level
'00 Mountaineer
If it’s not too late for you to return the Stage 8 kit, I would recommend using a different style lock nut, like the one from Giant Motorsports. I have the Stage 8 and hate it. Pain in the butt to install, and I keep bending the teeth on the sheet metal piece that goes on before the circlip. I loathe anything that requires snap ring pliers, and that kit requires using them multiple times. I think next time I need to take everything apart I’ll be replacing it.

Or you can disregard everything I just said and buy mine for a deal! :)
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Well, crap.

I looked at the lock nut from Giant Motorsports. It uses the stock inner nut and lock washer and is really just a outer nut with a clamp. Still have to deal with the possibility of spinning the washer, like I just did. I have never had a issue with the D44 outer nut coming loose.
 
Last edited:




Stic-o

Elite Movie Star
Elite Explorer
Joined
September 1, 2002
Messages
13,791
Reaction score
475
City, State
Lake View Terrace, CA
Year, Model & Trim Level
'91 Navajo '99 XL '16 XLT
I was going to go tent camping up there next week, but now I'm waiting on parts.
I'm open 5th to 7th if you're going to be up there.
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Maybe...

The parts arrived today. The spindles were coated in oil so I sprayed them down with brake parts cleaner, then painted the portions that will be exposed. I also wiped out the hubs and repainted the outsides. Will work on it when time allows.
New rear shocks came in yesterday, Bilestein 5125's X 4. They are about 3/4" shorter so I can run them straighter to help with body roll. They came with boots already installed. Think the easiest way to remove them is to cut them off. Never liked shock boots.
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Looking at the Stage 8 kit, I can see why it would be a pain to install, but I like the fact that there is no outer nut that requires 150 pounds of torque. One thing I don't understand is why they machined three snap ring slots into the nut when the inner slot should be all that is needed. I will give them a try. I have pulled the front axle apart maybe 3 times in five years, and as long as I didn't ruin a inner axle seal pulling the shafts, I shouldn't have to get in there for a few years. I also have a pair of long snap ring pliers that will make it easier. I installed the shafts, spindle bushing and spindles this morning. That's all for now.
 


410Fortune

Flood Season
Staff member
Moderator
Joined
August 3, 2000
Messages
25,081
Reaction score
1,301
City, State
NORTH IDAHO, 7B
Year, Model & Trim Level
B2 "Slightly" Modified
pics!! I want to see this stage 8 kit and what you are going through here......... pics or it isn't real!!
 


mounty71

It's green, not gray.
Elite Explorer
Joined
February 3, 2007
Messages
3,597
Reaction score
178
City, State
Oakland, CA
Year, Model & Trim Level
'00 Mountaineer
Yeah I wondered the same thing about the 3 slots.
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
I'm not going through anything since I haven't even made an attempt at installation. I was wrong about the three snap ring grooves, there are two, so you can start the nut from either side.
Behold
20190623_195912.jpg


20190623_195919.jpg


20190623_195953.jpg


I should have it wrapped up tomorrow after I schedule the next Padres homestand security staffing. Then I will report back.
 


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
I got both sides finished up today. The Stage 8 bearing nut kit seemed to be very well made and didn't take me any more time than OEM. I had to move the crown nut 3 or 4 times on one side, but it went straight on the other side. Having them means that I have to bring a pair of long nose snap ring pliers along for long distance expedition type trips.

I have basically rebuilt the front axle over the past few months; axle shaft U-joints, ball joints, repacked wheel bearings, new spindles and bushings, new brake pads, new hub seals and fresh diff fluid. Longest job of the day was getting one of the axle shaft end snap rings to seat. 30 minutes of wiggling the lock out and shaft end, and pushing the shaft outward before it finally snapped into place. I'm glad I ordered a new set of the Wild Horses spindle bushings. I tried to knock the bushing out of the damaged spindle and it didn't come out without damaging it. I left the other in the still good, but very old spindle for a spare.
20190624_150120.jpg


The ball joints I pulled out were AutoZone's with a lifetime warranty. I replaced them with Moog's, but did return the old joints for a new set. More spares to figure out where to store, then forget about where I left them.
 

Join the Elite Explorers for $20. Gets rid of the ads!

Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private Conversations, and more. Join Today. Your support is greatly appreciated.




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,101
Reaction score
927
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Today while I was putting the front tires back on, I noticed the pre-load on the driver side bearings was loose. One thing I really had down with the OEM bearing nuts was getting the pre-load set right. I have always set bearing pre-load by feel, and this is a whole new learning curve. Mounty, you were right about the crown nut thingie being a pain. I tried every notch combo, then ended up resetting the pre-load on the nut and the crown nut dropped right into place. I had to tap it slightly to get the snap ring to fully seat. I think once I get used to it, it will not be any more of a pain than the OEM nuts. With the Stage 8 system, there doesn't appear to be any way the nut could ever back off.

Now I am wondering if when the washer spun I put too much pre-load on the bearings and damaged them. They looked great so I reused them. I repacked them by hand like I always do, and didn't notice any slop. I will have to keep an eye on that side for a few local trips to make sure.
 


Thread starter Similar threads Forum Replies Date
S let's see your steering box on gen 2 sas Offroad Projects 4
ovrlndr Jay's '92 SAS on F150's Offroad Projects 1
KurtECV The Black Pearl SAS and build Offroad Projects 362
G 2001 ex SAS project Offroad Projects 4
C Chato's '98 V8 Mountaineer SAS build Offroad Projects 4
9 2000 5.0 sas question Offroad Projects 3
F Dana 44 purchased, SAS questions! Offroad Projects 7
L SAS on tons and 40" Offroad Projects 2
SVO42 mushy brakes after SAS Offroad Projects 6
A 2005 sport trac Dana 30 sas (Version 2.0) Offroad Projects 24
madbutcher Madbutchers shitmachine sas Offroad Projects 93
1 D30 sas/soa Offroad Projects 4
F FullBlownModz Dana 44 SAS Build Offroad Projects 18
D Project "Twisted Sister" SAS Front Dana 44, Rear Ford 9" Offroad Projects 46
A Explorer SAS or not for daily driver? Offroad Projects 1
boominXplorer Superduty D50 axle for SAS? Give me your thoughts........ Offroad Projects 7
JTX JTX's Return! 1997 Mountaineer Build Thread SAS/4wd Conversion Offroad Projects 65
CodePoet 1st Gen SAS Toyota Steering Box?? Offroad Projects 3
W Woody's SAS Build Offroad Projects 4
MidnightRebel07 2003 Sport Trac - SAS, SOA started and here's a sneek peek. Offroad Projects 118
I Getting closer to my full width 3 link sas need some help Offroad Projects 5
T Ford explorer sas project Offroad Projects 5
Stic-o 2nd gen SAS steering rubbing on exhaust manifold Offroad Projects 17
A sport track dana 30 sas project Offroad Projects 97
R 2002 Sport Trac SAS rack/pinion Offroad Projects 4
jprentice94 1st gen explorer sas Offroad Projects 20
B SAS for 2002 ford ranger Offroad Projects 0
D dersch6221992 Dana 44 SAS, with a rear SOA Offroad Projects 18
T 99 Explorer 1 ton SAS Trail Machine Build Offroad Projects 10
W 99 mounty sas thread Offroad Projects 0
K SAS to do or not to do? Offroad Projects 4
blueka Pickle 2.0 - Full Width SAS/SOA 4406 swap Offroad Projects 208
D 01 Sport Trac SAS Offroad Projects 33
C 94 explorer. Need help with SAS Offroad Projects 1
Y YoungMounty's '97 Mountaineer SAS Build Thread Offroad Projects 14
N SAS with ABS? Offroad Projects 24
X xeek's full width sas Offroad Projects 74
Stang5lgt Bronco II SAS Dana 30/8.8.... Offroad Projects 7
C Rocky Mountain Ranger '92 SAS Offroad Projects 32
Stang5lgt Project Lazyboy SAS... Offroad Projects 277
M 94 Re-SAS....leafs to links Offroad Projects 7
jjaganashi Gauging interest on SAS Offroad Projects 10
jjaganashi SAS "Betsy" 1-ton Offroad Projects 90
M mjc79's sas project Offroad Projects 7
LIFTEDXPLODER96 oh ya know just another 2nd gen sas in the works Offroad Projects 34
1-MEAN-X Project Green Hornet '01 Sport SAS Offroad Projects 159
turboexplorer Turboexplorer's Full Width SAS Build Thread Offroad Projects 965
D My no-budget 91 Sport SAS Offroad Projects 37
Four0Sport Jack's SAS version 3.0 Offroad Projects 270
C SAS leaf springs front Offroad Projects 2
Similar threads


















































Top