mjenk430 02 Sport Trac SAS

jperry7783 · April 24, 2011

mjenk430 said:
That's exactly what it was. One of the needle bearings had fallen down into the cup when I slid the cap on. That was my 1/16" of an inch. Got them together last night.

Its always good when its an easy fix.

RockRanger · April 24, 2011

Randy’s Ring & Pinion
Yukon YG D44-488 = 203.40
Yukon F8.8-488 = 265.17
Shipping = 0.00
Total = 468.57

Dont forget install kits if you are doing the gears yourself. also you will probably need a different carrier for the dana 44. It will depend on the gear ratio that the axle had in it when you bought it. Or instead of the carrier you might be able to use "thick gears" if they are available.

MidnightRebel07 · May 9, 2011

Any updates, gotta keep the Trac namesake alive in this setion.

mjenk430 · May 9, 2011

MidnightRebel07 said:
Any updates, gotta keep the Trac namesake alive in this setion.

Thanks for your interest in the build. Waiting on parts at the moment. I've got the axle built hub to hub (minus gears). Waiting on parts to hang it under the truck. UPS says everything should be delivered today. If I get a chance I'll snap some pics of everything tonight and update my parts list. Hope to start cutting out old suspension Friday.

MidnightRebel07 · May 9, 2011

Cool, I just paid my '03 Sport Trac last week so that frees up another $450 a month I can start saving up for my SAS, SOA. I just bought new Cragar Soft 8's with 33x12.50x15 GoodYear DuraTrac's so I might be waiting about two years that way I can save up enough and get use from these tires. Plus I just ordered new upper/ lower ball joints, axle shaft seals so I'll get some use out of them too.

OffTrac · May 9, 2011

Wow, I can't believe I just now found this thread. I will be following this one closely.

MidnightRebel07 · May 9, 2011

Damn Hugh, you're slackin', LOL. :bsnicker::wavey: :dpchug:

mjenk430 · May 9, 2011

Some photo updates...

Dana 44 Front Axle1

Dana 44 Front Axle2

Dana 44 Front Axle3

Spring Perches and U-Bolts

Crossmember, Shackles, Hangers, and Shock Hoops

Steering Kit from Ballistic Fabrication is on back order. Hope it comes before I get to that point.

mjenk430 · May 9, 2011

Updated parts list in first post.

As you can see, decided to stick with the leaf springs rather than a linked setup. When it came down to it, I just don't have enough confidence in my fab skills to tackle the linked setup. Maybe in the future, once I get some more experience under my belt.

Question regarding the U-bolts: BJ's Offroad shipped 5 u-bolts with the TT Fabworks perches, 3 "skinny" & 2 "fat" ones. I assume the extra u-bolt is to let you decide whether to use a skinny or fat one at the outside of the short axle side? My problem is I wanted to reuse the u-bolt plates from my 74 axle (you can see them sitting under the axle in the pics above). One of the plates fits 2 skinny u-bolts (long side of axle) and the other plate fits 2 fat u-bolts (short side of axle). On the short side of my axle, one u-bolt has to be a fat u-bolt over the pumpkin and the other is a skinny u-bolt over the axle tube, but the plate doesn't match that configuration. What has everyone else done?

RockRanger · May 10, 2011

http://www.pirate4x4.com/forum/showthread.php?t=978380&highlight=

If your steering stays on backorder long enough this might be an option. As far as the u bolts, I reused the ones that I got with axle. It has been so long I can remember the sizes that they were.

MidnightRebel07 · May 10, 2011

Where'd you get the crossmember for the front? I've seen the guys on the S-10 forum use the same crossmember on S-10's and I'm wondering where to look?

I'm looking at starting to stockpile the parts for my SAS and need to start really looking for the parts.

The axle looks good man. :thumbsup:

mjenk430 · May 11, 2011

MidnightRebel07 said:
Where'd you get the crossmember for the front? I've seen the guys on the S-10 forum use the same crossmember on S-10's and I'm wondering where to look?

Chevy S-10 Solid Axle Hanger Kit

It's actually designed for the S-10 but I saw where another user on here had used the kit for their explorer, so I thought I would give it a shot. Here's the link to j_mazala's SAS thread: 98 XLT Dana 44 on Leafs

I will still have to do some fabrication on the rear mount because the leafs on the dana 44 are a little wider than the frame rails (I would have had to do that anyways). But the front crossmember should save me some fabrication time.

MidnightRebel07 · May 11, 2011

Thanks, I thought that's what that kit was. Pretty cheap too for only $219.

mjenk430 · May 12, 2011

Got the suspension, 4" superlift, and stock differential dropped this evening.

Untitled

I have off until Monday so hopefully I can make some major progress this weekend. Still need to remove the rack and pinion. Then it's time to break out the plasma cutter and grinder. Lots and lots of grinding. Not looking forward to that part.

Time for some sleep. I sit at a desk all day long, I'm not used to all this physical work.

Brandon96 · May 12, 2011

Do you have a buyer for the SuperLift front kit? If not keep your fellow Virginians in mind!!

: let me know!

Awesome work so far man! :thumbsup:

mjenk430 · May 12, 2011

Brandon96 said:
Do you have a buyer for the SuperLift front kit? If not keep your fellow Virginians in mind!! : let me know!

Awesome work so far man!

It will definitely be going up for sale once I get everything sorted out. I will let you know.

Any good wheeling spots down your way??

Brandon96 · May 13, 2011

mjenk430 said:
It will definitely be going up for sale once I get everything sorted out. I will let you know.

Any good wheeling spots down your way??

ehh not so much my way, but if your willing to travel towards Harrisonburg, even the Lynchburg area let me know, I'll go in a heartbeat. I know some places / got some buddies out there with some land that will put that thing to the test!

Also, I appreciate the consideration on the Superlift.. I've been PM'ing the crap out of people trying to track down a used one. I can't afford to quit college just to afford a new one.

mjenk430 · May 15, 2011

OK. I have some concerns. First, the pictures:

Leafs Tacked in Place

I am using the stock 74 wagoneer springs for mockup. I will probably go with a 2" lifted spring once I decide exactly where I want it to sit. Like the new wheels/tires?

Spring Mount

Doesn't that frame look nice? I wish the inside and bottom already looked that clean. I still have A LOT of grinding to do!

Front Spring Mount

Location of front crossmember/spring mount.

Front Crossmember

As you can see the front crossmember is as far back as it will go.

Rear Spring Mount 2

Still need to make some gussets for the rear mounts.

OK, First concern: Is the angle of the shackle too flat?? At full droop, it is straight up/down. When it compresses it shouldn't swing up much further, because the leaf is almost flat already, and the spring can't get any longer. I don't know? What do you guys think??

And my major concern: the location of the axle. As it sits, the axle is 4" forward of the stock location. I will have to do some major cutting to the front bumper to get it to work. I sat the front bumper cover back on the truck and sat my 36" tires up next to it and it looked really goofy. I know most of you who have done the SAS have moved your axles forward, but 4"?!? I can't move the mounts back any, the front because of the radiator, and the rear because of the body mount. (The rear wouldn't be a big deal to modify the bottom of the body mount, but the front would be a PITA to either raise the radiator? or make a new crossmember). The way I see it, I have a couple of other options, the spring perches have three possible locations to sit the springs. RIght now I have it in the middle hole. I could place it in the front hole to move the axle back 1". I guess that's a start. Or I could flip the spring front to rear because the spring is shorter from center pin to front mount than it is from center pin to rear mount. That would move it back 2" I would have to drill out one of the mount holes though because the bolt sizes are different on the front than they are on the rear. Is there a reason I'm not aware of for the spring being longer in the back than in the front? If I buy 2" lift springs (like the ranchos or maybe the trail-gear leafs) will the center pin still be offset or is the center pin centered? What do you guys think I should do?

j_mazala · May 15, 2011

My fronts pushed forward about 4" with the Marlin Crawler springs that I'm running and it looks fine once I trimmed up the bumper a bit. Run your centering pin in the offset hole in the perches to bring it back an inch. For the shackle its my understanding that a more laid back shackle angle will make the springs fell softer while a more vertical shackle will have them feeling stiffer when going around a turn, as long as the motion ratio isnt effected by any binding or bottoming out the articulation shouldnt be effected. The only thing you dont want is for the shackle to invert and that will happen if the shackle is in line with the spring during full droop or full articulation. I think the Marlin springs are an inch shorter than the waggys so i didnt have the problem with the body mount but hack it out if you have to, the bottom of its doing nothing

mjenk430 · May 17, 2011

Will I be able to have a driveshaft made that works with my stock transfer case or do I have to change transfer cases?

mjenk430 02 Sport Trac SAS

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