Completed Project Turboexplorer's Full Width SAS Build Thread

[turboexplorer]

[MENTION=266592]Accarguy[/MENTION] The headlights I ended up getting off of Amazon. The HID's I got from http://www.ddmtuning.com/Products/DDM-HID-Kit-Slim-Ballast-35W-or-55W Mine are the 55W HID's.

Both have been great so far despite how little I have been able to drive the truck.

 

[turboexplorer]

All I can say is I'm sorry, and I wish I could think of the solution. I'm stumped. If it is the output shaft, is it cheaper to get a whole new case? If so, would be a good time to change to a NP231 or 241. I have the 231 and really like the gearing and the Teraflex 2 low conversion. I got mine with a AA slip yoke eliminator already installed for $300. The NP 241 has a 4:1 low range. The junk yards are full of them, and there is a lot of aftermarket stuff.

I have the 4R70W trans so it would be a bit extra work for either of those cases I think from the little I looked on them, not positive though.

might be a long shot, but if your tranny mount has that much play in it maybe it has something to do with it. Might be exaggerating the normal function of the u-joint

It really isn't weak I would have to show you a picture to see how tight the 4406 is in there with a Double Cardon and its just a fitment issue not really a weak mount issue. But however I have corrected that so shouldn't be an issue moving forward.

wow just killed some time this evening reading through this thread. what a great write up and documentation of this build!! seriously dude you really own the phrase built not bought. probably one of the nicest EXs ive seen on here. inspired me to start working on building up my ex again. keep on building and wheelin man!!!

Thanks I appreciate it! Can't wait to get out wheeling again. Been far overdue.

Is your new shaft a double cardon also? I swear my old vibration was just the fact of a double cardon joint on the 4406 slip yoke. A D/C joint has a much greater rotating mass and any play in the slip could cause a vibration. All slip yokes have some play, its the nature of the beast.

Yes it is a Double Cardon. In theory it should be the better and smoother option. I do agree that the weight would exaggerate any issue and if the mass would be less would be better as well since it is a very fast rotating weight. Ford did run several versions with the Double Cardon on the 4406 and didn't have an issue. I also ran it for 7,000 miles and never once had an issue until the issue lol. Been a crazy few weeks so Explorer has just been left alone since its fully together and it can be moved. I am really wanting to get it out and stretch its legs. Wish I had a better drive to get it repaired but don't look forward to further headache chasing things down.

I did go to several junkyards 2 weekends ago looking for cases that I can swap over so its 100% a different case to eliminate all possibilities. But each manual shift case I found had been moved by a forklift and the fork had lifted the trucks by the rear drive line and they where badly bent so if that's a reason for my issue I didn't want to chance it so didn't end up pulling any of the cases, wasn't interested in swapping possible issues for the same issues.

May go look again this weekend if I have some time.

 

[Accarguy]

[MENTION=266592]Accarguy[/MENTION] The headlights I ended up getting off of Amazon. The HID's I got from http://www.ddmtuning.com/Products/DDM-HID-Kit-Slim-Ballast-35W-or-55W Mine are the 55W HID's.

Both have been great so far despite how little I have been able to drive the truck.

Awesome thanks. Do you think you can post some pictures with the hids in? We're they a direct fit or did you have to do some modifications?

 

[FR-425]

So, bent shaft, had rebuilt, vibrates, rebuilt again, vibrates, rebuilt again, vibrates, on and on.

Did not vibrate before the damage. All other possibilities eliminated.

And still I have to say it's the drive shaft. I hope you have another choice for a shop near by.

 

[Kirby N.]

In disagree. If tom woods sent you one that's money. Nothing but good things heard and experienced from them everytime.

On the chomos for the fw 8.8, they are available I have seen them on full size broncs. I almost bought an fa bronco axle with a set of mosers in it. I bet if you call yukon or another manufacterer they would have them.

 

[turboexplorer]

So, bent shaft, had rebuilt, vibrates, rebuilt again, vibrates, rebuilt again, vibrates, on and on.

Did not vibrate before the damage. All other possibilities eliminated.

And still I have to say it's the drive shaft. I hope you have another choice for a shop near by.

I have had the first drive shaft redone 3 times and then ordered the 100% new Tom Woods shaft and the vibration didn't change at all so between all the changes including a 100% new shaft I hope that is eliminated.

In disagree. If tom woods sent you one that's money. Nothing but good things heard and experienced from them everytime.

On the chomos for the fw 8.8, they are available I have seen them on full size broncs. I almost bought an fa bronco axle with a set of mosers in it. I bet if you call yukon or another manufacterer they would have them.

Maybe I will have to look further for full width 8.8 shaft options when I get this issue figured out.


Think I have no choice but to do a new transfer case for the truck. I pulled the rear drive line and ran it and cant see the rear transfer case output shaft bent visually so really I am completely stumped. No idea, now I need to go to bigger changes I guess (as if new gear sets, rebuilt detroit, new shaft, went through case isn't enough) So will swap out the whole case and go from there. If it is still there I will follow the path of [MENTION=12558]boominXplorer[/MENTION] and go to a standard rear drive line and see if that's an issue. for that I REALLY wish I would have kept the Expedition rear shaft I had in it before the SAS as I could swap that in and change rear pinion angle and see if that's an issue. I no longer have that shaft as I figured I wouldn't need one.

 

[sirhk100]

I would think with the speeds your output shaft, driveshaft and pinion are spinning, even just the slightest bend that you can't visibly see would still be felt. I know my local driveline shop balances their driveshafts at 4000 rpm. Seems your shaft is not the issue though with all the replacements you've done of it. Very slightly tweaked output shaft or pinion though maybe?

 

[turboexplorer]

I installed a new gear set and there was no change so it isn't the pinion shaft. Only thing left is the transfer case.

 

[MidnightRebel07]

Time for an atlas II.

 

[sirhk100]

Yup, there it is... Atlas 2 is your only solution! LOL

 

[FR-425]

Just for shins and giggles have the Tom Woods shaft checked for balance.

My money (your money) is still on the shaft.. .. ..

 

[4wheeltom]

Crack open the T-case and check all your bearings and shift forks. Had a oil pump seize up in my old F150 that caused the forks to wear causing a nasty vibration. Fixing something worn out in the case would be cheaper than replacing

 

[FR-425]

Crack open the T-case and check all your bearings and shift forks. Had a oil pump seize up in my old F150 that caused the forks to wear causing a nasty vibration. Fixing something worn out in the case would be cheaper than replacing

He already did.

 

[turboexplorer]

Crack open the T-case and check all your bearings and shift forks. Had a oil pump seize up in my old F150 that caused the forks to wear causing a nasty vibration. Fixing something worn out in the case would be cheaper than replacing

Already did and didn't find anything that was a noticeable concern at all. Only thing I can think of is if something is bent somewhere and isn't visibly obvious.

Just for shins and giggles have the Tom Woods shaft checked for balance.

My money (your money) is still on the shaft.. .. ..

I have 2 shafts now and both are the same can't imagine that 2 shafts feel the exact same. The one has been gone through 3 times and for the most part everything is still the same.

Time for an atlas II.

Yup, there it is... Atlas 2 is your only solution! LOL

I wish that I could but still having the same issue mentally. If I could 100% guarantee that it would fix the issue I'd buy one tonight. The other issues with that is both shafts would need to be redone again (Grrr just bought new one) and would need to fab a place for the shifters. Wish I knew what it was then I could better spend money on wants vs needs. I would like to spend that $ on suspension parts not a T-Case since I have no complaints on the 4406 until possibly this issue.


I have been to the junkyards several times with no luck. I have found a bunch of manual shift cases but almost every single one has been lifted by the drive line when they are moving the trucks around the lots apparently so if that is a reason for my issue then I surly am not going to swap one out for the same issue. I will ask through my work tomorrow to see if LKQ has a 97-03 manual shift case that has lower miles etc on it and may buy it that way. A bit more money but don't have to pull it myself and I can return it if the issue is not fixed. This time (when I find one) when I swap cases I am not going to install the front shaft any of the skid plates etc etc until I find the issue. Tired of pulling it all fully apart every time.

Blah, I have a Moab trip planned for several days in July so would like to find the issue sooner than later. lol, only been since FEB I think since this all started.

 

[4wheeltom]

Totally forgot you already went through the case. Could your pinion flange be bent, not really sure if that would cause a vibration or not but I'm running out of ideas at this point. And it seems to be the only thing you haven't replaced.

 

[turboexplorer]

Replaced pinion flange when I put the fresh gears in. So that's been replaced to. It looks very sad sitting in the garage, only been out once since Feb.

 

[turboexplorer]

I bought some 6 ton jack stands, they just showed up today. Now I can safely run the truck in my garage and try to narrow it down further. I have Moab in a few weeks and not confident that I will have a truck to run, but o well there is more to do in Moab than wheel. I want to though.

 

[gmanpaint]

Changed your mind on wheeling it, until it breaks?

Or is the vibration that bad, it's unbearable for long periods?

 

[turboexplorer]

Very unbearable. Feels like it would really fail when it does. If I where to though I will put in the original drive shaft and use that one to fail. Then run the Tom Woods shaft after whatever is replaced. Hard to want to drive it until it fails, want it fixed, but don't want other issues or being left on the road somewhere.

 

[turboexplorer]

Had the Explorer's out to light up the neighborhood a bit. Want to drive it again.