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Bkennedy's SAS and Rebuild Thread


As some of you know, I am working on building a parts list for a shortened Dana 44, long radius arm with coil overs SAS. 5:13 gears to match my rear axle and an ARB, maybe an electric locker. I have a pretty good list so far. At the same time, I am going to swap out the rear drum brakes for discs off of a 99 Explorer.

Please note: The plan is to keep this project as simple as possible with mostly off the shelf parts. I am not a fabricator, just a decent welder with a what I would consider the minimum required tools (chop saw, cut off wheels, air tools, welder, etc.), who likes doing his own work. Your opinions are welcome, but what I really need is technical advice. I have been thinking about this for several years and now have the time and cash to make it happen. Please keep on topic with your advice and don't go off on a side track about how you would do it as a four-link, or caged arms, or leave the axle full-width because that is not what I want. I want a simple-ish set up that works.
 

BKennedy

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Got the Explorer diff filled and its back on all four feet. At today's weather conditions, it took about 20 minutes to fully empty a one quart bottle of Lucas 85-140 hanging above the diff with a tube into the fill port, so it was about an hour filling the diff. Going to take it for a drive tomorrow.
 


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410Fortune

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I ordered a DIY header kit from Speedway about a month ago it was out of stock.... it came in and they actually called to see if we still wanted it!! NOW THAT is customer service.
Will be using speedway more often....along with the usual rock auto and summit......

Glad you got the diff filled now go test drive! Hopefully without the headache
 








BKennedy

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I took it for a short drive over to the parent's house on Friday. Drives the same, vibration still gone, I guess I fixed it. I did drive over to a area we used to go off-road and camping at when I was young. Its all private area's with huge houses, which was no surprise since its on the edge of Ranch Santa Fe, but it used to be a bunch of dirt trails by a nice stream. I remember going there with my grandfather in his 47 Ford Panel Van to catch crayfish. I spoke with a security guard who said there is still a public roadway going down into the canyon, and pointed out the entrance to me. I drove down a easy dirt grade to the same concrete water crossing I remembered from long ago. All the side trails are blocked off and its some type of habitat for endangered whatever now. The road goes through to Elfin Forest and was a little bumpy so I got the tires dirty anyways.
 












BKennedy

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I took the Explorer for a drive in the back country on Wednesday, about 120 miles. Freeway, highway and 30 miles of dirt roads. The dirt roads go from a county maintained road, to a forest road that is not a 4wd trail by any means, but runs along the sides of some very deep canyons in the Three Sisters Falls area near Julian. I am always impressed at how my trail rig seems to cruise down the highway so well. Its gutless, but its only noticeable on long grades.
 




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