Completed Project Stic-o's 2nd gen. radius arm/coil SAS

Well it's Finaly Time to Start this thread.

Intro
In April of 2006 I will be doing a Solid Axle Swap on my '99 Explorer XL. Through the entire prosess I will be takink pics and updateing when there is is new info. I've pretty much always known I was going to do a SAS in my truck all along. For this reason, I have never but a dime into my front axle. I just never saw the point if I was going to rip it out.

The Plan

I plan to run a High Pinion Dana 44 full width in the front. I will be using Early Bronco Coils, posiablly 5.5" lift coils. I am still unsure of what I will be using for Radius arms, as we are still in the works. I would like to do a 3 link in the front but I don't think it's possiable with the cast wedges. I will be running 5.13 gears and plan to use anywhere from a 35" tire to a 37" tire, depending what I find. In the rear, I will be going to a 86-96 full width 8.8 off a Bronco/F-150. This will give me the ability to keep my speedometer, as well as reuseing my current locker, BTF Cover, and Disc Brakes. This will also give me a 5x5.5 pattern, and width almost dead on with the front. I would also like to move the rear leaf springs to the outside of the frame with the FW 8.8 to get rid of the spring hangers under the back doors that we all get caught on.

There alot of things still unsure, and I will figure it out as I go. Unfortally only small things will be done, until late March. Lack of funds will keep me from doing much until then. The axle will be set to go in the truck in April sometime though. Now let get to the goods. Pictures


The Meat

A side dish of parts

I can't wait for dessert

 

[Stic-o]

Come on guys on running 3.73's and 33's now, it can't get any worse

 

[hiridin]

well i was just going to say... 4.88's would work for 35's but yer not sure if u want 35's or 37's. i'd figure out what size tire yer going to run before u decide on a gear ratio. i say 5.13's if u go with anything over a 35. since yer auto or i assume u are 5.13's and 35's would be running rpms a little high. but with 37's 5.13's would be the way to go. imo ofcourse. u already said yer going to retire it to offroad only one day. y put highway gears in it? well not exactly highway gears but pretty close... 4.88's and 35's is almost the exact rpms as 5.13's and 37's.

 

[hiridin]

Most guys I know with 5.13 cant do over 60 MPH in 2wd without rapping out their OHV 4.0L, or so I have been told. To me this would get old REAL quick.

Am I off base here?

even at 75mph im not even 3k rpms. but i do have a manual. but i'm also only running 35's.

 

[410Fortune]

35's + 5.13 and 5 speed = under 3000 at 75? Wow, I pictured it more like 3500 RPM, but thats why I asked

Thanks!

 

[Michael]

<cough>5.13</cough>

X2

I would love to be able to go lower.

And 410, It'll run 85+ down the freeway. The little V6 has no prblem with the RPMs.

 

[410Fortune]

hmmmmm thanks! I learn something everyday...

 

[FROADER]

The reason I was asking about the off-road only or not was for the gears too. I want to got to at least 5.13 when I can.

 

[Stic-o]

are 5.13 availabe for 8.8?

EDIT: Never mind, I just found all the way to, 6.14's

 

[hiridin]

are 5.13 availabe for 8.8?

EDIT: Never mind, I just found all the way to, 6.14's

6.14's? wow i thought 5.13's was the lowest u could get. where'd u find that at?

 

[CodePoet]

I'm using 5.13's for mine...planning on running 35" tires too, i think/hope it'll be great on the trail.

 

[FROADER]

Stic-o, BKennedy is running 5.13s with his 35s.

 

[Jefe]

Most guys I know with 5.13 cant do over 60 MPH in 2wd without rapping out their OHV 4.0L, or so I have been told. To me this would get old REAL quick.

Am I off base here?

Without Overdrive, yes you would be screwing yourself.

Some quick calcs:

Me on 35's: (known fact)
70mph @ 2600 rpm
80mph @ 3000 rpm

.75 OD vs. my .70 (700R4)
70mph @ 2800 rpm
80mph @ 3200 rpm

5.13 & .75 OD
70mph @ 2900 rpm
80mph @ 3350 rpm


Me on 35's & no OD:
60mph @ 3200 rpm
70mph @ 3700 rpm
80mph @ 4250 rpm

5.13 & no OD:
60mph @ 3350 rpm
70mph @ 3950 rpm
80mph @ 4500 rpm

Thats all assuming still running 35's. 37s and 5.13 is dead even with 35's and 4.88

EDIT: And yes, I do drive 80 mph. Its actually the most comfortable cruising speed for my truck. 65-75 = 80+ = like a cadillac

6.14's? wow i thought 5.13's was the lowest u could get. where'd u find that at?

5.38 is the highest you can get for the HP D44. He was reffering to the 8.8. So the max you can go to match a HP D44 and an 8.8 is 5.13.

 

[Stic-o]

6.14's? wow i thought 5.13's was the lowest u could get. where'd u find that at?

8.8 6.14's

I only found up to 5.89's for a D44, but in my case I need Revese cut, so only up to 5.38's like Jefe said

 

[Ken Cooke]

Stic-o,

Maybe you can join Chris Glass on one of my upcoming Level 4 runs to Baja when the project gets completed! Good luck, man...

 

[Stic-o]

Wanted to get some thought's here... I'm thinking of ditching the whole radius arm bit and going with a 3 link Here are my ideas. Weld the tabs for the links where the sway bar mount normally are. Then run them back to some frame mounts, probably about where the Trans mount is now. This pulls the links in pretty close to match up with the frame. Then weld the spring plate straight to the top of the wedges (probably with a small plate under to fit all the imperfections), but in about 3" so, blocking the frame is not necessary. Then just run the tab for third link about where you see in the pic. , back to another frame mount. I didn’t put a mount in the pic for the trac bar, but you get the idea. I still would need some mounts for some shocks, but I was thinking to mount them probably on the back of the wedge. I know the cast is a pain to weld, but I thought the idea is worth throwing around.

Let the Riping begin

 

[JoshC]

I really don't know anything about the D44. I know they have the wedges for the radius arms. I'm not a fan of radius arms at all, IMO i think they limit flex as compared to a link system. So i'm liking your idea of going with links. Why not cut the wedge off? Here is where my ignorance of the axle comes in. Is it something that can be cut off? If you can get it down to the axle tube, is it cast or mild steel?

 

[bmxking5]

Those are built in...if he had a 77 or earlier F150 axle (broncos of that time were not full width), he could cut them off...like mine, which are being cut off to move them in.

 

[JoshC]

I gotcha, thanks

 

[frdtrckmnrich]

It is possible to weld these with a good wire welder. I've done it when i narrowed my axle. If you decided to link this axle what are you going to do with those radius arms? I you would be interested in selling them let me know..They would be perfect for my fullsize.Thank you.

 

[zainyD]

Linking it might be a bit of a challenge especially with the 78-79 D44 that you have. I would stick with the radius arms as you already have them and far less fabrication is involved. It's your truck though so best of luck with the SAS.