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Project "Twisted Sister" SAS Front Dana 44, Rear Ford 9"

Hey guys,

So I started a SAS thread almost 2 years ago. Lots have changed since then. But I am finally ready to start my SAS! Originally i wanted to go with a custom 3 link set up but after reading Stic-O's tread and realizing that he has the same axle as me and was going through the same issue as me with the cast on wedges. so even though i really want a 3 link im going to go with the radius arms. think it will be the easiest to do and fairly cheap too.

Current Truck Spec:
2000 Mercury Mountaineer AWD V8 174k miles.
24edmb9.jpg


Current idea
Dana 44 front on custom wristed arms with coils
http://www.broncoii4x4.com/wristed-arm/wristed-arm.php
Stock 8.8 SOA regeared with wheel adapters
37" tires on beadlock rims

This will be my trail rig/ rock rig, plan to still drive it to and from will NOT be a trailer queen (yet)

Donor vehicle is a 1978 Ford F150 SuperCab. im getting the Dana 44/ 9" and all linkage etc.

Current Concerns i need input on...
1. keeping the ford 8.8 vs the ford 9"
2. best rim/ tire combo

Here are the goals...

Summer 2015:
-Buy Dana 44, Ford 9" Rear- Picked up 7-11-15
-Recondition/ Rebuild Axles

Fall 2015
-Purchase everything for SAS
-Start to Cut off all IFS on truck
- Box in frame/ reinforce frame rail

Spring/ Summer 2016
-Place front axle
-Place rear axle
-finalize everything
-Exo cage
-Bumpers, Sliders, and winch added
https://www.universal4x4.com//four_wheel_parts/rock_slider_kit
http://www.chassisunlimited.com/product/bumper-parts/rock-slider-gussets.html
http://www.jcroffroad.com/product/XJDIYB/DIY-MJ-R.html
http://www.jcroffroad.com/product/XJDIYB/DIY-XJ-F.html

ANY input you guys have will be great. i am still in the planning/ buying phase so right now im ready for input if i need to make a decision or change my plan.
 


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FR-425

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My 99 did not have a speed sensor in the transfer case, I have a manual 1354 case note with no sensor and the speedo works from the rear did sensor. I believe the 95-98 trucks did have a sensor in the transfer case

Either way he can still put the tone ring in the 9"
 


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




FR-425

Used to be a road here.
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My 99 did not have a speed sensor in the transfer case, I have a manual 1354 case note with no sensor and the speedo works from the rear did sensor. I believe the 95-98 trucks did have a sensor in the transfer case

You are correct, some do and some don't, apparently it depends on the type of instrument cluster i.e. electronic/analog and whether it has the 4 or 5 speed automatic. The 2000 mountaineer did not come with a manual t-case.
 




dersch6221992

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Second gen = 1995 -2001

The speed sensor is in the transfer still on a 2000. The tone ring in the diff is only for the ABS.

You can mount the tone ring in the 9". You need to grind out the case a bit for clearance and drill a hole for the sensor. Not too tough if you have the right tools. You can, for a couple hundred bucks have a machine shop do it up.

Best part is you only need to carry the 3rd member and not the entire housing to the shop.

Here's a link with pics of a 9" with the tone ring mod.

http://www.therangerstation.com/forums/showthread.php?t=89605

This would be the better way to go than mess about with wheel adapters. Cheaper too.

But if the tone ring is in the transfer case why do i need to put one in the axle?? wouldnt the speedo work of the transfer case then?

i should add that i am going to do the BW4406 manual tcase swap soon.

and i honestly think figuring out how to convert the 9" from drums to rotors will be way more expensive and complicated then regears/ locking the 8.8 and throwing some adapters on it.
 




dersch6221992

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dersch6221992

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dersch6221992

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dersch6221992

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