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Dana 44/60 swap in 91 explorer

Started a couple weeks ago on swapping fullwidth dana 44 and 60 in my 91 sport. Pretty much stock explorer, other than the rust that wasn't a factory option.

Here's the specs on the swap:

front axle: 73 F150 dana 44, 4.56 gears, detroit locker, flat top knuckles, chevy disc brake conversion, custom high steer arms, custom steering links, wristed arm, 5.5" wild horses PR coils.

rear axle: 79 F350 full float dana 60, chevy disc brake conversion, 4.56 gears, ARB locker, spring over suspension lift.

Not doing much else other than the axles right now. Sorry I don't have pics, my main computer crashed and it has all the pics right now. Using old laptop in the mean time so I'll get some pics up as soon as I can.

Got a brand new set of meats sitting in the garage waiting for the swap. 36x13.50x15 TSL IROKS on white wagon wheels.


Here is a link to the post on RRORC.com that has some pics. CLICK HERE
 



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bmxking5

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Awesome. Good luck on the swap. :D
 






j602

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Excellent. That thing's gonna be loaded. One question/comment though, 4.56's will be a little high for 36x13's won't they?
 






cableguy

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eventually it will have a doubler or an atlas. I still want to be able to drive it on the street occasionall if need be.
 






cableguy

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Here is the final product. Started this project June 1st and finished it july 14th. Took a weeks vacation in there so ended up having about 30 days worth of work into it. Wheeled it pretty hard for 3 days at Chubfest and had no problems whatsoever. Here is a link to some pictures. Still can't post pics here.


Click here for pics of final product
 






j602

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Looks great! Nice to see you got it done in a relatively short amount of time too! Where did you get those D rings from? Did you just slide them through a hole in the frame? I've considered doing that but couldn't find a D ring wide enough for the frame rail.
 






rino351

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That thing kicks!!
Very nice work sir, and in short order!
 






bmxking5

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^^What they said. :D Looks great man. Looks like it wheels great too. :thumbsup:
 






cableguy

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D-rings are from a local tractor supply store. I welded them to the frame just under the bumper. Seem to be pretty strong (haven't had to use them yet). It wheels great, very smooth. Need some beadlocks so I can air down to get the full effects of the tires, but other than that, not gonna change a thing!

Thanks for the compliments!
 






j602

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Yeah I started searching eBay after I posted that and found the exact same ones, weld on and everything. $20 bucks shipped.
 






TheFox88

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That is HUGE! Good job! :thumbsup:
 






jrgaylor

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How did you set up your radius arms? wristed/heims etc...
Did you trim any of the rear wheel opening for the 36's to fit
Looks nice :thumbsup:
 






cableguy

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Stock radius arms - wristed on passenger side. I have yet to pull the pin. Those pics are with the pin still in. I wanted to wheel it for a couple days before I pulled the pin to get more flex.

I moved the front axle forward 2 inches, but still trimmed the fenders quite a bit. I folded the fenders under about an inch on both the rear and the front. The rear has about 2 inches out of it also. The only place it rubbed was against the firewall behind the front tires. Still need to beat all that back a bit to keep from ripping up my new tires.
 






jrgaylor

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Once you pull the pin post up some shots of the increase in travel :thumbsup:
 






cableguy

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Cool! Might be a while. The checking account/credit cards are still a little bruised after this whole deal. Don't plan on another run till November, but I'll be sure to take the camera with me.
 






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