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Completed Project Turboexplorer's Full Width SAS Build Thread

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Got back from a Moab trip a few weeks ago. Was amazing! Got to spend some time with my Dad and brothers and some time on the dirt enjoying beautiful Utah. Put roughly 200 miles on the truck in Moab and about 750 total for the trip.

Have some adjustments I would like to make so going to knock out a few these next few weeks. From lights to pull rear axle strip and refresh it. (Going back to original gear set that was in the truck, it's quieter. Current gears etc has some noise on deceleration even though pattern and pinion bearings are great with no concerns.)

Pulled down rear axle yesterday and stripped all parts bearings races etc. Fresh paint bearings etc and original gear set headed in. Also going to go through the original leaf pack, clean paint etc and reinstall. The current "HD" leaf pack is stiff and it's been a long time but from what I remember they were much better, plus don't tow with the Explorer much anymore.

And heck while I'm at it going to have the rear driveline lengthened 1 1/8" to put the slip spline in the back of the t-case further in. Still has a slight vibration at 65+ so will push it in a bit more as the vibration is from the heavy double cardon not quite being supported close enough.
 



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Went through locker, no wear at all. Still in great shape.

Pinion setup and ready for ring gear and pattern check.
Axle fully pressure washed out and ready for paint after gears are loaded. Been 12 years since it was painted.

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All done w/axle. Disassembled original Ford leaf springs, sanded and painted. Will assemble them today. Also got lengthened driveline back on Friday. Tom Woods is an incredible place to work with. Dropped driveline off on Wednesday they lengthened and shipped it Thursday and it arrived Friday. For $70. Great place and amazing service!

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Axle and springs done and in, drive shaft lengthened and in. I have had a 50" curved light bar for 9 years or so. So I finally did mounts, turned out great.

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