BMXking's Axle Swap 1st gen. Coils/Radius Arms!!! | Page 38 | Ford Explorer Forums - Serious Explorations

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BMXking's Axle Swap 1st gen. Coils/Radius Arms!!!

Well, I finally decided to start a thread on it. For those of you who don't know, I will be doing a full-width swap. High-Pinion Dana 44 front and Ford 9" rear. I am still looking for the HP D44, but I picked up the 9" Monday. I have never really done a lot of work on axles, so this will definitely be a long process, but I have already done a lot of research about this(and am still learning a TON). I plan on doing as much of it myself as I possibly can, but will have a shop do the regear for me.

FRONT AXLE
-1977 F-150 HP D44 Full-Width $200 - Moved Forward ~1.5”
-Myers Machine Coil Seats $40 shipped
-6* Pro Comp Pinion shims under coil buckets (to fix coil angle) $18
-CAGE Offroad 5.5” Coil Springs $150 shipped
-Coil Buckets Spaced Out 2.5" (3/16" x 2.5" x 6.5") $FREE
-Bronco Graveyard 78-79 Coil Spring Tower, Pair $90.80 shipped
-F250 Shock Towers $28 shipped
-Stock Axle Shafts(for now) $FREE
-Warn Premium Hubs $72
-Extended, Plated, Heimed, Wristed 1978-1979 Bronco/F-150 Radius Arms $222 shipped
-CAGE Radius Arm Mounts $FREE w/ R/A's
-Adjustable Superlift (p/n 1080) track bar (76-79 Ford f150/78-79 Bronco) w/ Energy Suspension poly bushings $125
-Skyjacker Stainless Steel Braided Lines for lifted D35 TTB's $90
-Bronco Graveyard 66-75 Early Bronco Adj. Bracket $45
-New F150 tie-rods & stock Explorer drag link (w/ red poly dust boots) $121
-Stock pitman arm $FREE
-Raybestos Professional Grade $19.95 shipped
-Powerslot slotted rotors $120
-Rebuilt Calipers $26
-Completely rebuilt (seals/bearings/ball joints/u-joints/etc.) $260.23
-Energy Suspension Red 7* C-Bushings $21
-Stock Explorer D-shaft w/ 1310 D44 pinion yoke for stock Explorer u-joints $FREE
-Rancho RS5000 shocks $20
-Bronco Graveyard Upper Coil Spring Retainers $22
-Rancho RS5000 steering stabilizer w/ custom bracket $25



REAR AXLE
-1983 Ford 9" $85
-Rubicon Express Anti-Wrap perches welded SOA $35
-Wild Horses Weld-On Shock Mounts $15
-Stock Springs w/ AAL and red rear poly bushings $10
-Stock Axle shafts w/ new bearings, seals, collars, etc $140
-94-99 Dodge Ram 1500 front rotors $58 shipped
-'76 Cadallic Eldorado Calipers w/ e-brake $155 w/ core calipers
-'78 F150 Extended Stainless Steel Braided Rear Brake Hose $45.34
-Custom Bent Brake Lines (w/ 3/8" ends) $8
-'79 Caddy Eldorado Brake Line end box thing $FREE
-7/16" Banjo Bolt for '76 calipers $5
-Bendix Brake Pads $35
-Speedway Motors GM Large Caliper bracket (7" mounting points) $40 2-day shipped
-Cut off mounting points from Ford 9" drums to use as spacers for the disc conversion (no longer a backing plate behind the shaft) $FREE
-Third Member from eBay (4.88s, mini spool) $150
-BC Broncos Disc Brake Conversion Wheel Studs $15
-Wild Horses Super Duty U-bolt Kits $60
-Extended/balanced rear driveshaft w/ stock 1310 to match the 1310 on the axle $123.63
-Skyjacker Nitro 8000 shocks for 2" lift Explorer $FREE
-Copper Third Member Washers $12.24

TIRES
-37x12.50-16 Maxxis Creepy Crawlers $400.00

WHEELS (5 on 5.5)
-16x8 Black Rock Crawlers $293

Grade 8 Hardware: $200

Tig Welding: $200

Parts Sold
-Stock Third Member w/ 3.50s and open diff -$50
-Lower Coil Mounts -$25
-Stock Radius Arms -$25
-31x10.50 Dunlop Mud Rovers, 15x8 black rock crawler wheels, Skyjacker 2” lift coils, drop-in K&N, front Skyjacker Nitro 8k shocks, Dual CB Antenna Mounts/Coax, and 235/75r15 spare tire, APC Ultra-White Bulbs, Radius Arm Bushings, Sway Bar Bushings -$415
-Ford 8.8 - 3.27 gears, 31 spline, stock limited slip, drum brakes, SUA, great condition. -$70
-Front Axle Shafts -$60

TOTAL: $3156.24





Future Upgrades:
Dana 44 -
-30 spline ARB
-Yukon 4.88s
-Warn Chromoly Inner and Outer Shafts, Moser Max 44 shafts, or Superior Axles
-Dedenbear flat top knuckles
-Blue Torch Fabworks Hi-Steer Arms
-Rancho RS9000X adj. shocks
-Late 70s T-Bird calipers (1/4" bigger piston, and still use Bronco pads :thumbsup: )

Ford 9" -
-New Strange Nodular Iron Case w/ 3.250 carrier bearing (STR-N1906) $359 Summit Racing
-Moser Spool and Axle Package Number 1 (ASP1) - 35 spline full steel spool for 3.250 case, 35 spline custom alloy axles, Axle bearings, 5 on 5.5, 1/2" studs $590 Moser Engineering
-Yukon 4.88s (F9-486) $139 PORC
-Daytona Pinion Support 3.250 case (STR-N1914) $115 Summit Racing
-R&P Master Install Kit for 9" Ford-3.250 Case, Daytona Pinion Support(R9FDD) $100 Moser Engineering
-Pinion Yoke 1310 - 28spline pinion (may upgrade to 1350 if I get a new t-case) (PY210) $90 Moser Engineering
-Axle Breather Vent $12 Bronco Graveyard
-Axle Truss
-Rancho RS9000X adj. shocks
-94-02 Dodge Ram 4x4 Powerslot Slotted Rotors

Now on to the pics!
 

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Thanks guys. I haven't been home at all today to get pics. I drove the Noma to school again so I could go straight to work to lower it. It looks/rides awesome..pics later (Sonoma). Caleb, there are plenty of hotels around here. I'll be busy for the next few weeks with graduation, work, etc. I'll talk to you about it on AIM soon tho. I'll try to get some pics in the next couple of days.
 



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what size shock did u get. i dont know if i missed that
 






I said that I was going to measure for them once it's all put together, but was planning on running ES3000s from an F250 w/ 4 or 6" lift (free). They won't reach at ride height, so I have some stock rear RS5000s from a King Ranch. They are about 4 inches longer, so they'll atleast reach at ride height. Like I said before, I'll measure for them later and get adjustable Ranchos.
 






oh it just hit me that u have told me that once
 






Yep ;)

Here's some pics that I had on the camera. I'll try to get pics of it all finished, later tonight. I got some pics from the awesome welds on the trac bar mount(the plate is getting bolted to the steering box). I'm pretty embarrassed to even say that I spent 45 bucks on that adjustable trac bar mount. The welds penetrated well, but they sure aren't pretty. They're half ass ground down...I would've spent less money cutting the steel and having my neighbor weld the thing from scratch.
 

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last one of the "work in progress" pics. ;)
 

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damn it you have to have pics of it finsihed by now......
 






For anyone wondering what size the allen bolts are for the Warn hubs, it's 7/64". It's definitely not a common size, so I didn't have it, but luckily my neighbor did.

In the last picture, you can see the driveshaft angle. I set up the perches the same way that 034x4, and others told me too. I always thought that the yoke and driveshaft were supposed to be an identical angle, but obviously not (Extreme 4x4 and Horsepower TV said to do the same thing that 034x4 told me). I've had it up to 50-55mph and it's perfect. You'd think that driving with a set of torn up BIAS PLY 37" Maxxis Creepy Crawlers and what I thought was a bad driveshaft angle, it'd have a lot of vibrations, but that's definitely not the case! :thumbsup:

Ok, here are the pics finally.
 

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Is your rear driveshaft a double cardan type? If it is, grind the spring perches off and re-weld them with the pinion pointed straight at the transfer case.
 






No, when I had it made, I was pretty much outta $$ and just had it lengthened. I decided that I'd just get a double cardan added if I had vibrations, but like I said, it rides really smooth...and remember this is after me coming from driving a nice lowered Sonoma. It's no Cadillac ride, but for 8" of lift, AAL, 37s, etc I think it rides great.
 






now go get it dirty!
 






bmxking5 said:
In the last picture, you can see the driveshaft angle. I set up the perches the same way that 034x4, and others told me too. I always thought that the yoke and driveshaft were supposed to be an identical angle, but obviously not (Extreme 4x4 and Horsepower TV said to do the same thing that 034x4 told me).


and what was it he told you?
 






This is his reply from a different PM. I don't have the PM that I sent (so that you understand what I said about #1 ,etc.)
"Close.
#1 is correct. T-case output is at 4*. So you want your pinion angle to get 4* so you don't have any driveline vibrations.
#2. Mounts the leafs on the truck, and on the bottom of the leaf, where the spring perches will touch, measure that. Mine were about ~2*.
#3. Set the axle on jackstands with the pinion at 0*. If you put the perches on at 0*, the spring would rotate the pinion up 2*. But you want 4. So with the pinion sitting at 0*. You want to weld the perches on at 2* (that is, the front of the perch is angled down, torward the pinion 2*) and thats who you get your 4* pinion angle.
Lemme know if ya got anymore questions, glad I can help."

Jason, I'm probably taking it offroad tonight or tomorrow. :D
 












bmxking5 said:
Jason, I'm probably taking it offroad tonight or tomorrow. :D

Cool, but there aren't any places that offer real offroading within 2-3 hours of here... where are taking it? You got a hookup that you're keeping secret? :p

And if you say Suwanee Creek or PIB I'll come torch it apart while you're asleep! :D



Bring it by one day next week. I'd like to take a look.
 






I won't be around much next week. I'll try to though. I don't know where we're gonna go offroad. Remember now, 1. this is the first time the new suspension has gone offroad, so I want to take it easy and not break something the first run out (atleast I know the welds are not gonna break!) 2. The front axle still has 3.50 gears, so I'm still 2wd, but atleast I can have 2lo. :)
 






oh ok.. 2wd only for a bit. At least it moves finally! Go ramp it on a receiving dock ramp. See what it can do. Or if the 4wd parts center folks left their ramp out there.
 






No, they took the ramp. There are tons of loading docks around here, but they all have sides on them :( But we do have a forklift at work. :D
 






looks great........
 



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Looks good. You have been talking about it for long enough!:rolleyes: You critized mine and a bunch of others if I remember right, so I think I deserve to scrutinize yours!!! :p I think you need to hack the crossmember. If you are getting any good amount of uptravel it will make contact. Mine made contact with 6" springs and a hacked crossmember on speedbumps. Of course yours is FW and that will make significant difference. Also, I think you will regret the steep angle of your trackbar- Good thing your mount is adjustable. You would get more travel with less bind if it were closer to level (speaking from experience- mine is super steep) it forces the axle to much laterally from droop to stuff when the tracbar is steep like that. You should move your tie rod over knuckle and move the Trackbar mount down a few holes. That would probably improve your travel. Lastly, I think I would brace that Tracbar mount or something. To only have it welded on the tip to that flat stock would worry me.

I dig the Bob Meyers coil seats! Get out there and wheel that thing!! It looks way to pretty- it needs some good dents! 2wd is no excuse!!
 






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