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

^^Searches ExplorerForum.com^^

Bkennedy's SAS and Rebuild Thread


BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Thanks, Burns.

Today, I made 8 gussets for the shock hoops before I was satisfied (messed up the first 4, plus the redo = 8). Did not get time to tack them in before I had to go out.
I did get the engine cross bar all mocked up. Check out the custom notched cross bar, fella's.....



No, I am not going to use that, its for mock-up. Need to go get a matching tube bent tomorrow.
After that, need to measure for the steering and tear it down for finish welding, then paint, then put it all back together, then put back all the crap I removed to get the hoops to fit, then work on the electrical, then lets not forget I still need to decide on bump stops or air bumps, then.......AAAAAAAAAAAAAAAAAAAAAAAAHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHRRRRRRRRRRRRRRRRRGGGGGGGGGGGGG!!!!!!!!
 


Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month option.

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
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Got the tube bent for $20 (10 a bend). They also said they will charge the shocks for $10 each.

Sent from my XT907 using Forum Runner
 




DB_1

Elite Ranger
Elite Explorer
Joined
October 23, 2001
Messages
3,798
Reaction score
41
City, State
La Quinta, Ca.
Year, Model & Trim Level
97 SC Ranger xlt
Too bad I don't live closer, I'd only charge 35 bucks for all that:p:
 




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
I have a question about coil overs and ride height. I understand the springs set the ride height. I was given a recommendation of 16" lowers and 12" upper springs for the ride height set at 5" of up travel. If the springs are not the same as the extended length, then there is the possibility of them coming out of the carrier at full droop. When I set the ride height for the shock hoops, I just measured out 5" of shock shaft length, and masking taped it in place. I woke up this morning with this on my mind, and I guess I won't really know until its all finish welded and installed.

I ordered a different wheel adaptor set. The one's I am using for mock-up have 12x1.5MM studs and I did not like the idea of two different lugs on the Explorer. Bought a custom set from http://www.motorsport-tech.com
Lifetime warranty, hub/wheel centric, and only 1" wide.
 
Last edited:




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Today and yesterday evening I was working for the Chargers, so not much done. Saturday morning I did get the cross bar and mounts, and some gussets all mocked up. Tomorrow I plan on welding up the lower shock mounts so they don't move, and putting the shocks in with springs to see what I am looking at for ride height.
Raider Retard...

Cross bar/brace..



The pics make the cross bar look closer to the engine than it sits. There is about an inch of clearance, and over that for the hood. There is not a whole lot of room in there.

I could tell right away how important that cross brace is when I knocked it into place. The entire setup is much more rigid.
 




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Maybe someone can help me understand this message I received from FOA. It seems like every question I ask about their shocks leaves me with another question, based upon their vague answers.
I asked them what brand/type of shock oil they used so I can buy a small amount to top off the shocks when I add the 90* fittings. I got this:

"We use an AW22 special spec hydraulic oil. Odds are high you won't be able to find it in small amounts. It won't hurt anything to use a 5wt shock oil in place of it."

Do you think this means:

A) Its okay to top off the existing oil with 5wt shock oil

B) The oil should be completely replaced with 5st shock oil
 




FROADER

Moderator
Staff member
Moderator
Elite Explorer
Joined
January 28, 2000
Messages
19,935
Reaction score
128
City, State
Huntington Beach, CA
Year, Model & Trim Level
1997 XLT
I would take that as: A

Since it won't be much at all compared to the amount that will be in the shock, just adding the available 5wt shock oil.
 








BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Getting close and looking great :chug:
Thanks.
Today, I have a roller! It was sitting on its own weight, for a little while anyway. Adjusted the coil over shocks and set it at ride height (might go up a little)
Need to do some minor adjustments. I think the track bar might be a little long, but it was only an eyeball estimate.

Droop-ish

Ride height-ish


With enough weight off front suspension to turn shock adjuster



Does this mean I can have 2" longer tender coils (I have 16" main and 12" tenders)??


Droop seems to be limited by the shocks so I will need limit straps. With the shocks out, the double cardigan joint in my front drive shaft starts to bind a few inches lower than where the shocks would limit travel, and the slip-joint looks good, so I think the shaft will work without modification.

Questions:

How much sag should I expect as the coils break-in?
Shocks are not charged in the pics, will it effect ride height?
 
Last edited:




Rick

Pumpkin Pilot
Staff member
Admin
Elite Explorer
Joined
February 8, 1999
Messages
32,104
Reaction score
1,013
City, State
Wayoutin, Aridzona
Year, Model & Trim Level
'93 XL Pumpkin Edition
Callsign
AB7FH
Looks like all your measuring has paid off. The ride height looks perfect:biggthump

I've never, not had a charge in my shocks, but I don't think it will affect ride height:dunno:

I have probably sagged 3/4 of an inch since new. I don't remember it sagging very quickly.
 




turboexplorer

Elite Explorer
Joined
August 23, 2008
Messages
1,943
Reaction score
18
City, State
Eagle Mountain, UT
Year, Model & Trim Level
98' XLT 5.0L 4X4
Callsign
Turbo
Charging shocks is worth very little spring rate. Will not be a noticeable difference.

If you run quality springs like Eibachs then you should see no sag in springs at all. Maybe after years and years of use but none in thousands of miles and many years of use. With my wheeling and 5,000miles of road use and 2 years old I have 0 sag on my springs. I had my coils out the other day and both uppers and lowers are still dead on 14" exactly what they where new.

Looking good though, congrats on getting it on its own weight that's a big step tha got me excited to finish mine!

Also, I have 3" or so of shock body above my coil retaining nut as well. If you don't have coil bind at full stuff there isn't a need for a longer upper spring. And to my knowledge they just use upper/lower or primary/secondary coils. A tender coil is a third spring on top of upper coil that is solely designed to keep pressure on the springs at full droop if it is needed. In your case and mine as of now it's not needed. Unless the right height is to high so to lower it you had to back the adjusting nut off to where there wouldn't be spring pressure at full droop.
 




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Thanks.
Some people call the top spring the tender, some call what you are calling the tender a helper spring, in a triple rate configuration. I like how it sits now, but I might get it about 1/2" taller before I re-adjust the track bar. That would bring the up-travel to around 5.5", which works for me.

Getting it back on the ground is huge. I was looking at it today thinking......I did that, it's going to work, all my planning has paid off, and it looks awesome!!
 




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Looking at the front drive shaft, I might need to clock the transfer case to bring the front output down. It will reduce the shaft angle and help clear the exhaust cross pipe. Having a NP231 with the AA adaptor will make that a fairly easy job. Will have to re-do (again) the skid plate for the transfer case. Think I will just remove it for now.
 




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Steering Question:

I am now thinking of going with TRE's instead of Hiem steering. I saw this, and I have a 20% off code from the vender.
http://www.wfoconcepts.com/pr/Inverted-T-Tierod-Draglnk-End-Kit/3163/4295/4486

What I don't like is having to use 1.5, .25 wall tubing. It is very wide and might cause issues. Is it possible to get 1.25, 120 wall DOM and sleeve it with a piece of 1.0, 120 wall DOM, so just the ends with the bungs would be 120 wall? Would that be stronger than the 1.5 while keeping the outer diameter smaller?
 




RockRanger

Elite Ranger
Elite Explorer
Joined
January 14, 2001
Messages
6,209
Reaction score
176
City, State
Fresno CA
Year, Model & Trim Level
86 ranger no more
Callsign
KK6TDL
Won't be stronger. I am using 1.5 x .250 tube for steering. I am glad I did. The tierod is still straight as the day I put it in. It has been bashed hard. Just make sure it will clear your diff cover.
 




gmanpaint

It's Always Something!
Staff member
Moderator
Elite Explorer
Joined
August 1, 2008
Messages
10,910
Reaction score
1,238
City, State
MO MO
Year, Model & Trim Level
94 & 95 XLT's
I chose the steering kit from Ruffstuff. It comes with the 1 ton GM TRE, and a special TRE for the Pitman. It's angled to accommodate for the lift. Comes with all the Dom too. Price was right, and they have 20% off sales all the time.
 




turboexplorer

Elite Explorer
Joined
August 23, 2008
Messages
1,943
Reaction score
18
City, State
Eagle Mountain, UT
Year, Model & Trim Level
98' XLT 5.0L 4X4
Callsign
Turbo
I agree. I'm glad I did as well I bumped mine really hard once and no issues. Also nice to know that you'll have no flex in steering components driving at 70mph. And my stuff was from RuffStuff as well on a 20% promotion code I believe.

Ill post on my build thread next week what I did to eliminate the tie rod roll. This last trip to Southern Utah, the freeway drive down was amazing super tight best it's ever driven. 0 tie rod roll now.
 




BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Thanks
I keep going back and forth like my wife in the shoe section at Nortstrom.
Eventually, I will decide.

Today, I kept messing around with trying to mimic the ride height, both the vehicle and the suspension, with no weight on the front. What a pain. Every adjustment I made to the right side, moved the left, and the rear suspension unloads every time I take the weight off the front. Finally got close, but now my side to side placement of the front axle looks even. When its on the ground and at ride height, the passenger side tires are out about 3/4" from driver side. I guess I just need to hack off 1/2" at a time from the track bar, set it on the ground, hack off, set it on the ground, etc...until its true.

I did get the placement for the limit straps and bumps. I am just going with some 1.75" diameter by 2" high Synergy poly bumps I already have. The limit straps will use my original axle shock mount location directly inside of the coil overs. Double sheer mounts, of course.

Due to the fact that I flat tow the Explorer behind my RV, I had limit straps with quick release pins mounted to the rear of the tires on the radius arms/frame to keep the suspension from unloading and riding up on the tow bar. It happened once, and my insurance company paid a lot of money to fix the damage. http://www.explorerforum.com/forums/showthread.php?t=326467 They allowed about 3" of down travel movement. I am figuring the issue will be ten-fold what is once was with the new suspension. Also figured out today that if I had not cut off the temporary towing limit strap mounts, I could have used them again. I got those all lined up using the existing shock mounts on the radius arms. I had a nifty plan of using longer bolts on the limit strap mounts to add the temporary limiting straps with quick release pins, but the long bolts might interfere with the coil overs, and would be hard to get to behind the shocks.
 




Stic-o

Elite Movie Star
Elite Explorer
Joined
September 1, 2002
Messages
13,792
Reaction score
475
City, State
Lake View Terrace, CA
Year, Model & Trim Level
'91 Navajo '99 XL '16 XLT
Won't be stronger. I am using 1.5 x .250 tube for steering. I am glad I did. The tierod is still straight as the day I put it in. It has been bashed hard. Just make sure it will clear your diff cover.
Same Here:thumbsup:

Mine taps by BTF cover with full lock, but that's about it.
 


Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month option.

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
7,113
Reaction score
930
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
So, this morning I get it back on its wheels and at ride height. It still looks like the tire is sticking out more on the passenger side than driver side. I get out the old trusty plum bob, level and tape measure. Yep, sticks out 1/4" more on passenger than driver. So I check the frame and its exactly 9" from the outside of the top of the upper ball joint to the plum line on both sides. Dead centered on the frame. So its the body that is different side to side.
I am guessing only I would every notice it, but there it is....
The passenger rear tire is the same, sticks out 1/4" more than the driver side.
Do I leave it alone and figure the frame is straighter than the body?
 




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