08' ranger SAS build up - Page 3 - Ranger-Forums - The Ultimate Ford Ranger Resource


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  #51  
Old 01-06-2010
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does anybody know what lube i can use to pack the inner part of the seals for the t case? i was told to use vaseline for the instal of the flange, but i believe vasiline isnt good for rubber,, correct?

or is it not necessary to fill the space with any grease? just use oil?
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  #52  
Old 01-07-2010
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its as complete as i can get it until i test the throws with a shifter. i quickly removed the spindle for the shifter arm to replace the o rings on the spindle body. i realized after that, i should of marked the spline to keep the arm positioned in the same position it was in before.i did notice a marking on the spindle where i could refer its positioning to. im pretty sure the torx bolt in the shift fork guide left particles on the spindle of the spline it was in, so i installed the spindle back into the case using that last resort method.

i tested it out by hand with the case open and in 4x4 low the arm is perfectly horizontal towards the transmission. is this true for any one else? can someone check their case for me? i want to get some sealant on the case and call it done and move on..

heres a pic of the positioning in 4x4 low..

note the arm is straight up and down.
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08' ranger SAS build up-006.jpg  
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  #53  
Old 01-07-2010
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more pics of my 'mock' assembly lol..
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08' ranger SAS build up-001.jpg   08' ranger SAS build up-002.jpg   08' ranger SAS build up-004.jpg   08' ranger SAS build up-005.jpg   08' ranger SAS build up-007.jpg  

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  #54  
Old 01-07-2010
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looks good dan, you went all out on that case. I think I would have just tossed it on. lol
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  #55  
Old 01-07-2010
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thanks, it went kinda slow, but im learning lol. i bought the case for $400 and put just over $100 into replacements and hardware. not toooo bad, plus it looks good too!
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  #56  
Old 01-10-2010
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ill be swapping out the rear axle in the recent future. i just got a hit at the local wreckers on a 2002 fx4 8.8 ranger rear end. its a 31 splined, trac. lock diff with 4.10. ill just pull out the 7.5 and throw in the new one if it looks good, but i might service it if i feel its worth doing. i plan to regear it and add a locker at some point after the front takes shape. luckily with this find i also found a dana 44 from a guy near me. he was selling a 44 and a 9" from a 73-79 and a 78-79 f150/bronco axles. the dana im looking at has 3.55 gears, 30spline, and ford locking hubs with the ford 5 on 5.5. so we will see if i get a reply on that sooon, but when if i get it, ill be doing alot of work on that. ill leave it at that for now until i get them. i'll eventually just space the rear out to match the bolt pattern on the front and make up for some width.

an update with other work;

>ive got my shop gathering the prices on a new output shaft, pan, filter, seals and required service components for my trans.

>my 1354 linkage is soon to be a done deal, and should be in the mail this week possibly. but the boot and bezel i want is hard to find..

>steering components; yota box & pitman arm, and custom lines are soon to be a done deal, and will be in the mail this week possibly.

Last edited by 08rangerdan; 01-10-2010 at 10:52 PM.
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  #57  
Old 01-10-2010
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yayy for steering!
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  #58  
Old 01-10-2010
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Isnt the Output shaft nearly impossible to find? Or am I thinking of the one for the LII manual tcase?
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  #59  
Old 01-11-2010
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i dunno but im just ordering a new shaft from the trans shop. they never left me stranded yet..

the rear and front axle is a no-go. i checked up on the rear today and the ugly thing came out of a 2002 4x4 'offroad' NOT the fx4 as i was told, that means its just a 28 spline 8.8. it would be just as useful as my 7.5 on my truck now. im now looking at 1 of the many explorer 8.8 axles. the front dana 44 was just sold out from under me so i missed out on the first 44. but i just got yet another hit on a wagoneer front axle that would be ideal for my project, complete with manual hubs! and it looks promising, i called this morning and we are just arranging a pick up for it but if all goes well i might have that within 2 weeks. but im starting to get excited, alot of the goodies are starting to fall into place.

Last edited by 08rangerdan; 01-11-2010 at 04:57 PM.
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  #60  
Old 01-12-2010
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i just got my quote for the transmission parts tonight; output shaft, pan, filter, seals, shift kit, and everything they reccomended to replace for servo and other mechanical weaknesses with the tranny came to about $600. since i will get a good deal on labour the shop will install the components and my completed t case into the truck. as soon as i get the shifter and find a 4x4 rear driveshaft i will finish that stage and focus on the suspension
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  #61  
Old 01-13-2010
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just picked, fresh from the wreckers is a 2000 explorer, 4 door rear driveshaft. this shaft came with the proper outputs for my needs, a 2.5" bolt pattern for the t case side and 3" for the axle side. it is approximately 47" resting on the floor, but it can be +- an inch or so when collapsed or extended. all the pivot points seem nice, so i will run it as it is but i will shine it all up and add paint, not bad for $100. my 1354 linkage is also now on its way, i picked up the shift bushing; 3L5Z-7335-AA to go with it, when it comes in. those buggers will run you 20$ a piece from the dealer!
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08' ranger SAS build up-001.jpg   08' ranger SAS build up-002.jpg  

Last edited by 08rangerdan; 01-13-2010 at 10:27 PM.
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  #62  
Old 01-13-2010
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yeah you better shine it up after what you did with yer t-case lol
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  #63  
Old 01-13-2010
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ya ha, it'll be even more fun then the t case, the sand blower just aint big enough to crunch the d shaft into so im cleaning it by hand. lol

Last edited by 08rangerdan; 01-13-2010 at 10:15 PM.
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  #64  
Old 01-18-2010
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its a good thing i decided to actually look at what axle i had on the rear. i had just assumed with a 3.0l, 2wd ranger that it would be a 7.5" rear end but when i checked the tag number it read, "V316A 410 88 7626" which would meen i got myself a 4.10 geard 8.8 rear end from factory, i was pretty surprised. since i planned to run a narrow width axle setup i will obviously use this axle for my rear end and use whatever gained funds to purchace a locker and new gears for it.

i started to wonder about the rear axle after the quick search for the driveshaft. im assuming the 3" flange on the axle was standard with the 8.8" rear ends and a 2.5" flange was standard on 7.5" rear axles. i didnt quite understand at the time when i found out i had a 3" flange, now i know..
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  #65  
Old 01-20-2010
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t case is completed and sealed. shifter came in tonight, tested it and works like butter. next week ill be getting the trans parts and possibly installing them next week also with the case and d shaft.

another d44 deal collapsed on me, nobody seems to follow through on a deal for me.

im going to start deciding what im going to subtle for, theres a few options left over for an axle. but im beginning to look at the d30 as a budget friendly and practical front end for the ranger.

benifits..

d30

-keeps my bolt pattern
-newer housing
-cheap parts, easy to find
-close to same width
-would match my rear axle quite well
-max tire size 35"
-would allow me to save enough money to consider a 3 link with coilovers...!
-practical axle to be used everyday with my stock power and still be plenty usable offroad

problems
-weak axles shafts and joints (but can be upgraded easily)
-smaller gear

ill be deciding what axle to use on friday because im taking a trip down to a friend who has a large assortment of axles to choose from and ill be buying something for sure.
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08' ranger SAS build up-002.jpg   08' ranger SAS build up-003.jpg  
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  #66  
Old 01-21-2010
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Personally, I wouldn't settle on a D30. You'll find a D44 with a little patience and will be much happier in the long run. The cost savings of a D30 pretty much go away when you have to buy stuff to beef it up.
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  #67  
Old 01-21-2010
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^^ i agree completely wait out for a dana 44 there are a bunch for sale over on TRS.
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  #68  
Old 01-21-2010
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ok well i'll see but i doubt i would be able to smoke a d30 with my truck, i think a 44 would be nice but finding something near by is impossible lol

new bad news, the driveshaft i chose for the rear is too short lol i need to extend it 13 inches. i think it came off of a 2 door then a 4 door, so ill bring it to the driveline shop to extend and balance the thing tomorrow. probably for the best anyway..

shift linkage cleaned and installed
Attached Thumbnails
08' ranger SAS build up-002.jpg   08' ranger SAS build up-006.jpg   08' ranger SAS build up-005.jpg  

Last edited by 08rangerdan; 01-21-2010 at 08:26 PM.
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  #69  
Old 01-22-2010
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Quote:
Originally Posted by 08rangerdan View Post
ok well i'll see but i doubt i would be able to smoke a d30 with my truck, i think a 44 would be nice but finding something near by is impossible lol
All I'm saying is give it a little more time. You might be surprised to see a D44 pop up when you least expect it.
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  #70  
Old 01-23-2010
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well i got back from my axle donor. taking a good long look around his property he had many d44 axles, all full width and looked enormous for what i wanted to do with the truck. in the end i wanted my vehicle to still look fairly stock, not alot of lift either. for a 4x4 conversion and sas i figure anything that would go on relatively easy is what i wanted. in the end i pulled up a good deal on a complete dana 30 hp. it is set up for coils and radius arms, i plan to go get a warn manual hub conversion for it and do the inner axles also. rotors and brake pads look good but i doubt the calipers are going to work properly. i ll see how they look when i get it apart but ill most likely get a better and stronger rotor for the truck along with the calipers. ill get new gears for it and probably leave it open diff for now. bearings seals and little stuff are going to be obvious replacements. for my ranger being a 3.0l and auto trans the dana 30 shoud be a good match for the truck and should allow me to have just a little more fun with it, which is what i wanted in the end. once the axle is built i figure out the links and we will have it up sometime in the spring or early summer.
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  #71  
Old 01-25-2010
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so today i got my new driveshaft from the shop,its now a total of 60" flang to flange.

i took my axle into work and began removing all the parts from it, the axle is a 1989-1990 Cherokee d30.after it was drained i first started removing the caliper bolts, then removed the caliper and disks. then removed the axle nut and harware. i removed the non servicable hubs and shafts, for some reason i had 2 different hubs on my axle. the one is a poor design with an external bearing seal that was riding on the rusty passenger side shaft, as you can imagine that hub was in need of replacing due to a contaminated bearing. the other is a true solid hub with the bearing seal built into the hub. that hub was acceptable but i will replace it also. i then cracked open the diff cover and pulled out the carrier and pinion assembly. i will instal new seals, bearings and shims at the time of the regear but i will keep the old ones intact until that time for reference.

the axle assembly now just needs the knuckles removed to replace the upper and lower ball joints. im not sure how to remove these because the knuckles seem very stuck on the ball joint tapers.

as the axle sits now i have left all of the seals in the housing and have filled the carrier with rags, i will take the core into a company to have the housing thouroughly cleaned and blasted back to new. then the knuckels will be removed when i figure out how to replace the ball joints, and then assembly will progress

poor designed hub on left and true sealed hub on right, new 60" rear driveshaft
Attached Thumbnails
08' ranger SAS build up-003.jpg   08' ranger SAS build up-005.jpg   08' ranger SAS build up-006.jpg  

Last edited by 08rangerdan; 01-25-2010 at 08:01 PM.
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  #72  
Old 01-25-2010
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my plans have changed for this axle build, since there is possibly a chance of upgrading in the future, i dont want to dump an enormous amount of funds into this axle. i plan to replace the stock shafts (maybe) and defeniately u joints with possibly stronger components, the hubs will be replaced with another set of the non servicable 'true' sealed hubs, i will get the old style out of the axle. i need a new set of backing plates, and then hardware, carrier/pinion bearings and seals, and ball joints all round, then a regear for the front to match what i put in the rear

Last edited by 08rangerdan; 01-26-2010 at 08:48 PM.
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  #73  
Old 01-25-2010
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does anyone know where i can get new backing plates to replace my rusty crappy ones? or is it even necessary to use them?
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  #74  
Old 01-26-2010
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so today i got i little more accomplished,

i removed the knuckles, i just needed to use a bigger hammer..
and then i began removing all the rotten, rusty mounts and brackets with the torch. ill need to take the axle into a mechanic to press out the ball joints from the inner knuckles, im not set up at work well enough to manage that removal. i think i need a mechanics touch with this lol. after work i went over to car-quest and picked up my new hubs which were $200 each, ball joints alone are $90 a piece at car-quest! ill talk to the mechanic first to see if he can get less expensive ball joint units, because ive seen them online for around half that price. tomorrow i will finish grinding the tube ends smooth then i will talk to the mechanic about the joints later in the day..

once i get to clean up, after sandblasting of the components im looking into powder coating the knuckles and axleshafts, just to keep those parts looking good longer then they would with just paint. i will just paint the axle housing since its so exposed.

the truck goes in for the 4x2 - 4x4 driveline swap on february 3rd. that will include the transmission rebuild, transfer case and extension housing install, and new driveshaft..
Attached Thumbnails
08' ranger SAS build up-001.jpg   08' ranger SAS build up-002.jpg   08' ranger SAS build up-004.jpg   08' ranger SAS build up-005.jpg   08' ranger SAS build up-007.jpg  

08' ranger SAS build up-009.jpg   08' ranger SAS build up-010.jpg   08' ranger SAS build up-011.jpg   08' ranger SAS build up-012.jpg  

Last edited by 08rangerdan; 01-26-2010 at 09:28 PM.
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  #75  
Old 01-26-2010
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if anyone can help me decode a dana 30 tag number off of my cherokee d30, please help me. i can only make out most of the numbers and still some may be incorrect..
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Last edited by 08rangerdan; 01-26-2010 at 05:24 PM.
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