Solid Axle Swap Progress Thread
 

Ok well i figured since my truck is pretty far along I'd make a post summarizing what all I have done and all of the specs of the build. Hope this helps some people so they don't have to read the whole thing.

2003 Ford Ranger Edge 4x4 Black
3" PA body lift.
Cut off IFS and all related bracketry.
1981 Jeep Wagoneer Spring under Dana 44.

Internal parts of Dana 44
Yukon 5.13 gears.
Yukon Master install kit.
Full spool.
Yukon Chromoly 30 spline inner shafts.
Yukon Chromoly 19 spline outter shafts.
All brand new brake parts (rotor, calipers, bearings etc)

External Front axle parts/set up
Parks Mike Parts Flat top Knuckles w/ ball joints and high steer arm studs.
Blue torch fab High steer arms (both sides)
TT's fabworks Spring perches and u-bolts.
Blue torch fab Kryptonite diff cover and bolts.
1.5" .250 wall Tie-rod/drag link with 5/8" heims.
RE1555 28" stainless steel brake lines.

Steering
1992 IFS toyota steering box from Foxfab.
Ported for hydro assist by Mild2Wild.
PSC hydo-assist ram.
Custom steering shaft (ranger and 'yota shaft mated together)
Allprofab one peice pitman arm.
Custom power steering pressure hoses.

Front suspension
Alcan custom leafs based off of 8 3/8" rise 7 leaf waggy springs, shortened ~6".
4.5" Stock ranger rear shackles.
No shocks as of yet lol.

Rear axle internal
1999 Explorer Sport Trac 31 spline 8.8.
Yukon 5.13 gears.
Yukon master install kit.
Full detroit locker.
Superior chromoly 31 spline, custom 6 lug shafts.

Rear axle external
Redrilled rotors to 6 lug.
Brand new brake parts (rotor, calipers etc)
7.5 Spring perches off of elliott's old axle lol.
95 exploder spring plates.
95 exploder u-bolts.
Stock diff cover and bolts.

Rear suspension
63" 1992 Chevy 1500 leaf springs.
4.5" stock chevy shackles.
Flipped, cut, and box shackle hangers.
Pushed forward ~6" front spring hangers.
24 (i think?) ES3000 shocks
Mild2Wild shock tabs.

Body
Dovetailed truckbed 17" at tailgate.
Added 2 1x1 square tubing bed supports.
Chopped bumper.
(When i get front fenders...)Cut front fenders.

Engine
MAC intake.
Pro-M MAF.
Half-shafted throttle body.
Ground throttle stop.
Motorcraft double platinum plugs.
Gutted last cat.
2 chamber flowmaster with turndown.

Interior
Door handle surround, floor cup holders, and radio bezel matching green satin paint as axles.
Relocated A/C controls to cup-holders.
Mounted CB in-dash.
Gauges changed to red.
Pioneer DEH1500 (??) headunit.
Sony 1200 watt 2 channel amp.
4 gauge Rockford wires/RCA's.
Custom sealed box i built for 2 Alpine type E 10's (don't have them yet though lol)

Exterior
Headlight mod
Blinker mod.
Camo painted grille and whats left of rear bumper.
60 watt PA speaker painted black behind grille.
MM9500 SE winch (not yet mounted.)

I think thats everything.

Well since all the carnage on the drive home from savannah, I have started my SAS early since i didn't want to dump any more money into my un-reliable, un-able-to-handle-35's IFS. So i am making this thread for pictures and updates as I partake in my SAS.

I am using a D44 out of a '81 wagoneer. Warn chromo-shafts, CTM u-joints, 5.13's, powertrax, CHC high steer knuckles, BTF high steer arms, 'yota IFS steering box, wagoneer 7-leaf spring packs SOA.

Here are some pics of what i have done so far.

This is how the D44 sits right now, all brackets cut off of axle housing, and primered waiting for parts to put her together.

Attachment 214297

This was taken this morning, everything that is taken off i removed sunday night, the day i got home, and no i don't waste any time lol.

Attachment 214298

http://img.photobucket.com/albums/v7...4/7a4551da.jpg

I just took these tonight, I have the front suspension crossmember cut off, all control arms, rack, calipers, shocks off. All i have left is to remove the driveshaft and the front diff and then i will cut the rest of the control arm etc. brackets off.

Here is my pile of crap parts that i have removed.

Attachment 214299

Passenger side frame rail.

Attachment 214300

And a view from the front, you can see the crossmember is gone and the front diff is the only thing left.

Attachment 214301

how much did u spend on parts for the axle? $1500??

Haven't bought everything yet, but estimated prices yes around 1500 for just the front axle parts.

EDIT: Draimen, thanks. :scool:

I like it that you're using the high-steer hardware. I HATE how so many trucks have the rod across the FRONT of the axle, down LOW where it's going to get whacked all the time. I never understood keeping that setup on an offroad truck.

Good stuff and keep it coming! :smile:

what happened to your ifs with the 35s?

the sas is gonna kick ass!

If you look at the thread in the meet and truck photography, my passenger hub bearing blew out going up I75 N. Bearing and knuckle are worthless, rotor is bad, caliper bracket is ground to 1/2 the thickness and the caliper is worthless. I had 36,000 on the truck.

Just got off the phone with classic city off-road in Athens and got 5.13's, full spool, install kit for the D44, and 5.13's, install kit and notched cross pin shipped to my door for $660. Thanks Bobby.

Also ordered my high steer arms from blue torch fab. And i was going to order my Crane high clearance knuckles but their shop is closed b/c they are moving until august 5th. So i have to find another source for flat top knuckles.

And lastly i ordered my u-joints, went with ox b/c they are about 100$ cheaper than CTM's and since i'm buying everything at once i wanna try and save as much cash as possible. When i get back in contact with the guy i'm ordering my toyota IFS steering box today. And i got all the brake parts (calipers, rotors, pads) on order as well.

Yes I am going to run a reversed shackle. The D44 is a narrow-trac waggy. It is not full-width. I am using Parts Mike's D44 flat top knuckles with BTF steering arms. The front drive shaft, i'm going to have a local drivetrain shop a friend works at lengthen it and i probably will run a double-cardan up front depending if it can operate at a steep enough angle for the amount of lift I will have. I might not keep the stock t-case so i'm not too sure on that right now.

Found Parts Mike's flat top knuckles. Got me a pair with spindle studs and balljoints installed. Also got in contact with another Mike for my steering box. It's on it's way as well.

....WOW, i could never tackle anything like that lol!! 5:13 gears are pretty high....hope you dont have any problems with it...good luck with the rest of it!

Thats gonna be awesome, can't wait to see how it ends up. Are you still going to run 35's?

Nope, 39.5"s. Either Irok 39.5x13.50's or 39.5x15 TSL's. Thats why i'm using 5.13 gears ;).

I'm removing the front diff tonight, cutting as much of the factory brackets off as possible and then i'll get some pics.

Gotta see how much of a PITA mine will be before i do anyone elses :headache:

UPDATE: Got some parts in today. Front and rear 5.13's with install kits. Full spool for D44. And my blue torch fab high steer arms. Them things are beefy as hell. On to the pics.

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EDIT: If anyone needs any of the **** that i'm taking off my truck, feel free to PM me with an offer on it.

Sent you a pm about some stuff.

Did you have any sort of lift kit installed, or was it a body lift??



Vic

He had the b/l...

Brenton

Damn Jey, that thing is moving quick. I wouldn't mind going up there to you, but there is no places to ride, so when you get done we could ride up to Tellico & I could be your camera b!tch or something...

Brenton

Aw c'mon i'd love to follow your 2wd up the trails there. Lol n/m camera ***** would be better.

With a SAS do you think that you will increase suspension travel alot ?

Edit: meaning do you think you will have a lot of travel like DBR 14" of travel

Not the same type of travel. I will have alot of articulation, but i'm not going to be able to go rompin' in the dunes at 30 mph.

wat kinda gears did u have in your old axles

4.10's.

glad to see someone posting this mod. i have seen a few rangers like this and it is bada$$. i am debating doing it myself too. keep a parts list and then post it when ur finished. good luck with the swap it takes balls to just cut the front end of ur truck off.

No, Brenton has LTB's, but practically the same thing... Good luck Jey!

Brenton

thats what I thought, there are no dunes around for me to jump anyway but there is some deep mud.