Starting full width D44 SAS...B4 I order, what do you guys think?? | Page 7 | Ford Explorer Forums - Serious Explorations

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Starting full width D44 SAS...B4 I order, what do you guys think??

Starting full width D44 SAS...FINALLY!!! (Update)

Like the title says..I feel that I am ready to begin my SAS and have compiled a shopping list. I'm wanting some opinions/thoughts/ideas about the list before I continue on. Also note anything I may have left out. Your help is appreciated.
There are a few things (in red) that I will need your help on, any ideas?
Things that I have/received are bolded!

D44 Front
-1978 Ford Bronco HP D44 Full Width (Moved Forward 2")

-78-79 Coil Spring Towers Pair (Broncograveyard Fab 1/4" steel brackets to space it out 2")

-Stock 1978 Bronco Lower Coil Retainer/Spring Cup (Turned around?/moved 1" in?)

-Wildhorse Rock Crawler 5.5" Black Coil Springs (Wildhorses4x4)

-Rancho RS9000 adjustables. I 've heard they give you 13" of travel

-Front Shock Towers F250 Shock Towers #E5TZ-18183-A

-Yukon 4.88 Ring and Pinion Gears

-Detroit Electrac Locker (DrivetrainSpecialists)

-Master Overhaul Install Kit (Broncograveyard)

-D44 Yukon Chrome Moly 4340 Front Axle Set (Broncograveyard)


-Extreme Outer Rebuild Kit (Broncograveyard)

-Caliper Left/Right Rebuilt (Local Napa)

-CAGE Offroad Tubular Radius Arms CAGE Offroad

-CAGE Offroad Radius Arm Mounts (Fab 1/4" Steel Brackets to space out 2")

-1994 Explorer Drag Link (Ford Parts Network)

-1978-1979 Stock Tie Rod (Broncograveyard)

-SuperLift Adjustable Trac Bar (Broncograveyard)

-78-79 Bronco Trac Bar Drop bracket (Broncograveyard)

Ford 9 Inch

Yukon 4.88 ring and Pinion Gears (Broncograveyard)
Detroit Locker (Randy's RNP)
Spring Perches (4WheelParts)
Master Install Kit (Broncograveyard)
WARN Leaf Spring Shackles (4 Wheel Parts)



2" Body Lift (liftkitdepot.com # PER792)

Wheels
15x10 Steel Rock Crawlers (Series 97) (4WheelParts)

Tires
36x13.5 IROK Radials (4WheelParts)
 



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I'll go ahead and take some pictures of um. one in and one out so you can see. I don't like crud in my axle tubes either and thats why I got these made.

The story behind this is, I ordered a pair for my D44, however when I got them it was for a Heep D44 and the axle tube diameter is larger then the Ford D44 so I asked a friend, who's a machinist, to make similar ones for my Ford D44.
 



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That's awesome. I'm interested in some pics as well. Possibly even a price quote. ;)
 






axle tube seal pics

here are the pics of the axle tube seals, with one of them installed
 

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Price?
 






I've talked to him about doing a little side business but we're not sure how practical it is. He had done mine out of his shop at work so he'll work on it whenever he has free time. How long it'll take to fab a Ford one will be determined on his work load. Also, getting the rubber seals on the fat end of the tube seals is another issue. the only thing we could come up with is that you purchase the heeps one from a company ( i bought mine from northridge4x4) and press out the 2 rubber seals and fab up the dimensions of the Ford D44. If you know a machinist or know someone who knows a machinist, that'll be the better way to go!
 






It looks to me like they are too big, The picture I attached shows how close the yoke on the axle is to the axle tube
 

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Sas Updates!!!

Its been a while since I last posted anything on here or even worked on my SAS project due to an unfortunate event concerning my bro-in-law in Iraq.

RIP BRO.... :salute:

But now I am back on track and getting this darn project rolling again. :thumbsup: :thumbsup: :D

I finished building up the axles and got the tires on them for easy transportation. My truck is now in a shop. The front and rear axles of the Explorer are now off and got some pics of the progress...

Picture11.jpg


Picture10.jpg


Picture15.jpg


Picture16.jpg
 






Very sorry to hear about your brother. I've been lucky so far with two cousins over there being ok so far... :crossedfingers:

Hope the swap all goes smooth for you from here. :thumbsup:
 






Glad to hear you back on track. :thumbsup:

Sorry to hear about your brother, I'm sure he was a great man:salute:
 






Thanks FROADER and Stic-o! Yah he was...is a great man. He accomplished the rank of SGT., which he had wanted to do since his dad was a SGT in the Hawaii County Police Dept, before an IED (roadside bomb) went off during a routine check.

As for the swap....it should go well since I have the green light to do whatever it takes to get-r-dun.... :thumbsup: :D :thumbsup:
 






Here are more pics of the rebuilt D44 and Ford 9 axles with the IROK's on:

Picture23.jpg


Picture17.jpg


Picture24.jpg


Picture22.jpg
 






Sorry to hear about your brother in law, my deepest condolences to you and your family.


Looks like you're coming along well with your swap. Looks like you've spend some $$$$ in parts!
 






Thanks zainyD!

Yah,.... I have spent quite a pretty penny on this SAS swap. But i figured it'll be well worth the investement in the end. I have an idea of how much I may have spent but I really don't wanna know the actual amount. :eek:

:confused:




:D
 






I have an idea of how much I may have spent but I really don't wanna know the actual amount. :eek:

:confused:




:D

I have a rough idea of how much I spent on mine, but ya, I don't think anybody really wants to think about the total.
 






Anyone here happen to know the importance/reasons of moving the front axle foward ~2"?
 












I was thinking of leaving the axle in the stock location too, but there's really no point in doing it that way. As has already been stated you need to move it forward for the driveshaft, tires, and trackbar to all fit better. This is especially true because of the clearance issues with the TTB engine crossmember.
 






Thanks guys!

One thing,...ok, i heard about the issues of the engine crossmember (the diff hits it at full flex) and the driveshaft (being that the stock explorer drive shaft will be 2 inches longer) but what about the tire and trac bar issues?

Will the 36" i am running hit the rear part of the fender? And does it mean that the trac bar will be going inward about 2" from the frame to the axle?
Could you please explain more about these issues? Just want to know all the reason for moving it before i start welding stuffs together.

Thanks again guys!
 






Thanks guys!

One thing,...ok, i heard about the issues of the engine crossmember (the diff hits it at full flex) and the driveshaft (being that the stock explorer drive shaft will be 2 inches longer) but what about the tire and trac bar issues?

Will the 36" i am running hit the rear part of the fender? And does it mean that the trac bar will be going inward about 2" from the frame to the axle?
Could you please explain more about these issues? Just want to know all the reason for moving it before i start welding stuffs together.

Thanks again guys!


Yes. You are going to have contact on the rear side of the front fender. I did. I moved mine 3.5" forward. This helped to make the driveshaft the right length, the approach angle better and clearance on the front fenders. I am running 37s and mine clear. I do have a small amount of contact 0on the front of the fender at full stuff, but that can be fixed easy enough. The back was getting complicated to trim. Trac bar? Ah, I don't think that is much of a reason to move it forward. You can mount the upper mount pretty much anywhere in front of the axle and put a bend in the trac bar or buy some joints with high enough misalignment. Mine has an "s" bend in it. I don't think moving the axle forward will help much with diff to crossmember clearance. Maybe in a FW or Low Pinion scenerio. Mine still contacts my crossmember at full stuff, though it is 3.5" forward. Any further forward on mine and the coil buckets would have been a challenge to mount- I cut my drivers and welded it over the frame bulge. I hope this info doesn't confuse you more. Get that thing done and get out and wheel it!!! :salute:
 



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Any updates? It has been over a month and I am getting worried.

Eric
 






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