SAS on a Sport Trac

[jackflash]

I am wanting to do a SAS on a Sport Trac? Has any one done this. What axle was used? Got pictures? Does any one know a good fab shop in the Houston are that could do some work?

I am not looking for anything over the top. I am wanting an expedition rig not a rock crawler. Max tire size would be 35s. I am thinking of JK Rubicon axles or a really well built D30. I am not looking for a full width D44 as I think they are to wide for the application I want (if you don't think so please say why).

 

[JohnnyO]

A guy named Chad is going to work on one soon. I've seen a blog from a guy in Iceland who built one. Gotta get back to work but I'll try to find it later.
Basically you want the front Dana 44 out of a '76-'77 Ford Bronco because it is the right width and has disc brakes. Of course after 32 years they're kinda scarce and pricey when you find them. I know a guy with an SAS'd Ranger who used a IH Scout Dana 44, which works, problem is the bolt pattern is different so he can't rotate the tires.

 

[JohnnyO]

Found it:

http://www.4x4offroads.com/4x4-project.html

Just for kicks, here is his blog detailing his trip across the U.S. to pick up his Sport Trac and ship it to Iceland:

http://www.4x4offroads.com/4x4-on-road-in-usa.html

Interesting to see a foreigner's take on the U.S.

 

[jackflash]

Thanks, I have seen this one. Looks sweet and is functional too.

 

[John_Rock]

Here's is the section on the board where some owners have documented their SAS projects. It's a mixture of 1st Gen and 2 Gen Explorers. The Sport Trac is in the 2nd Gen category.
http://www.explorerforum.com/forums//forumdisplay.php?f=63

Here's the best 2nd Gen SAS I've ever seen. The guy did all the work himself. Don't bother asking any questions on that thread. The guy sold the truck and is no longer an active member here.
http://www.explorerforum.com/forums/showthread.php?t=94815&highlight=jefe

But you state that your purpose is not rock crawling, but to have an expedition vehicle. So why would you need an SAS? Just get the Superlift and some lockers. You will save yourself a lot of money.
Check out what other Sport Trac owners have done on this thread:
http://www.explorerforum.com/forums//showthread.php?t=202351

But if you are hell bent on SAS and spending lots of money, a couple of the Demon4x4 guys I know had their SAS done at Texas Auto Gear. They are near I-45 and Little York.
http://www.txautogear.com/

Or if you want to get a 2nd or 3rd opinions on fabricators in the Houston area go hangout at Spring Creek Offroad Park in Spring when they have the Mud Bog competitions. They have them on the 3rd weekend of every month.
http://www.springcreekoffroad.com/
http://mudbog.springcreekoffroad.com/calendar.html

You could get a look at different people's rigs and find out who did the work.

 

[yellowford]

A guy named Chad is going to work on one soon. I've seen a blog from a guy in Iceland who built one. Gotta get back to work but I'll try to find it later.
Basically you want the front Dana 44 out of a '76-'77 Ford Bronco because it is the right width and has disc brakes. Of course after 32 years they're kinda scarce and pricey when you find them. I know a guy with an SAS'd Ranger who used a IH Scout Dana 44, which works, problem is the bolt pattern is different so he can't rotate the tires.

He would be better off with what he stated as the Rubicon front 44 axle, if he gets one from a TJ it will also have the correct bolt pattern and come with an ARB locker.

 

[Squirrelmaster]

I know jackflash, as I'm the one who directed him to this board, and he is thinking of swapping both axles, front and rear, with the ones for a JK because he can get them (relatively) cheap from Mopar as complete assemblies, and switching both would give him a 5 on 5" bolt pattern all around.

Discuss.

Tom

 

[jackflash]

Thanks for the major feed back Jonestone that is what I am looking for.

As Squirrelmaster stated, I am thinking about changing both front and rear axles to a set of Rubicon JK axles. Sounds crazy I know, but you can get complete axles with brakes, gears, and e-locks for $1300 each brand new from mopar. In that you have a choice of gears as well from the stock 4.10s to 4.88s. Any ideas on why this would not work?

The reason behind me wanting an SAS setup for an expedition vehicle is because of maintenance and strength. While I am very very impressed to see what Johnstone has done with his Sport Trac, I want something a little easier to maintain and a little stronger too. As stated, I am not wanting a rock krawler but I want something that can drive to some pretty hard trails, like the Rubicon Trail, and then be able to drive me all the way back to Houston. Not only that but I want to drive to the Arctic Circle, and down to Baja, and to the tip of South America. Hell with the way the economy is going; I am not going to have a JOB anyway.

Plus, come on a Sport Trac with a Straight Axle up on 35s. That is just cool.

 

[John_Rock]

Just my experience talking here....

I've been offroading with a few of the D44 SAS Explorers, like Rick(the owner of EF), Froader, Mudd*****(Demon4x4 owner), and Michael Bouknight(EF and Demon4x4 member). They have all broken **** when offroading.
Now maybe an Explorer with D60 axles front and rear might be able to do a lot of offroading with out breaking.

You just better be comfortable with the amount of spare parts you might need or in the knowledge to be able to fix whatever breaks or to be able to get spare parts.

Let me know if you want to go hang out at Spring Creek sometime and see some rigs.

 

[jackflash]

Jonestone thanks for the link to txautogear.com I looked over their website and I think they can help me. I'll have to give them a call.

One question for you, how did your D35 hold up to the 35" tire you were running?

 

[Dannyboy]

If I was going to drive from Texas to the Rubicon and back I think you need to hear 3 words.






Dixon Brothers racing

 

[John_Rock]

Jonestone thanks for the link to txautogear.com I looked over their website and I think they can help me. I'll have to give them a call.

One question for you, how did your D35 hold up to the 35" tire you were running?

I'm probably one of the few that has broken a 2nd Gen D35, but that was probably due to the drain plug I installed in the cover. It's after adding a locker to the front axle that you will start to go through CV axles. But they are not hard to change. I've see the solid D44 guys breaking hubs, axles, and u-joints just as much as I break CV axles.

 

[John_Rock]

BTW, I still have no lift in the front of my truck.

IFS vs SAS and/or Experience/Good Spotting vs Incompetence/Bad Spotting....???

Year: 2003
Place: Barnwell Mountain Recreation Area near Gilmer, TX.
Challenge: Rock Garden

In May of 2003 I visited BMRA with an offroad club from DFW. I knew a guy from Ford Truck World that was going out there with his 78 Bronco so I thought I would go check it out. I had plenty of fun with the DFW club doing the trails up there. Two of the trucks were fullsize Blazers with stock solid front axles on 35" tires and they attempted to do the rock garden at BMRA. Both trucks bailed on the rock garden about 1/4 to 1/2 way through. Being I was from Houston and don't know these people very well, I definitely decided not to try the rock garden. I wasn't going to chance breaking my **** and have no way home. Out of the big group from DFW the two Blazers were the only ones to attempt it.

Less than 2 months later I am back at BMRA with Demon4x4 and Explorer4x4 members. Two of them from Houston. With the help of excellent spotting from Michael Bouknight I went 98% of the way through the rock garden.

The point of the story??? Chevys suck! Ford Rulez! Seriously though... get some experience no matter what you do. And keep the rubber side down!

 

[jackflash]

Your making me think that I should just TT, shackel it, Body lift it, then throw on some 35s and call it a day. Of corse I would have to lock it and regear it as well.

How well does the TT ride down the road?

Do you of any good skid plates out there?

 

[John_Rock]

There are pro's and con's to everything.

Like I said, I am more than willing to hangout sometime like at Spring Creek.
Gregg XLS lives up in that area. We could have a little mini ST 4x4 meet.

But, this weekend I am heading to hangout with Txplates up in Marble Falls. I might be able to get him to scratch up his ST this weekend.

 

[jackflash]

That sounds get but mine is down and out right now. I am in the process of rebuilding my front end right now, and I have a cast boot on my leg right now. Not really able to move around right now.

 

[IZwack]

There are pro's and con's to everything.

Whoa careful there, you're starting to sound like project management material buddy

 

[John_Rock]

Whoa careful there, you're starting to sound like project management material buddy

Just buddy now? And not dear?

Hey JackFlash, check out IZWack's Tube Buggy Explorer project...
http://www.explorerforum.com/forums/showthread.php?t=205817

Before - 2nd Gen SAS

In Progress - 2nd Gen Buggy

 

[jackflash]

That's crazy. Looks awesome.

 

[IZwack]

Thats all PhotoShop work -- the vehicle doesnt look anywhere near that. I mean cmon, I've got a little more sense than chopping up a perfectly good vehicle!