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rs182 07-18-2011 07:40 PM

02 1500 sas
I am about to start my solid axle swap on my 02 1500 4x4 so I thought I would start a thread for you guys here. Longs story on why but I have a dana 44 out of a 78 bronco complete with radius arms (which are getting lengthened and replacing bushings with Johnny joints) coil buckets, and steering. The tentative plan is as follows starting next Tuesday (out of town until then)
I dont plan on lifting the truck much. Currently has after market torsion bar keys and add-a-leafs in the rear. I am trying to keep it close to 3/4 ton height more or less (that where it is now)

-remove diff and steering, cut off stock ifs brackets and cross member
-fab custom cross member
-start measuring and fab custom radius arms
-build frame mounts for said arms
-trim frame and mount upper coil buckets frame is 36" out side to out side and lower coil buckets measure 37.5 inches inside to side. Pretty tight.
-mount jeep quick ratio steering box where needed and build adapted input shaft coupler
-get brake lines made
- i think stock drive shaft will work with high pinion 44
-button up lose ends
Drive it!

I will start posting pics as soon as I can!

RedRam10 07-19-2011 11:14 PM

Can't wait for a progress report with all those photos.

rs182 07-27-2011 09:34 PM

Got most of my parts in
jeep agr quick ratio box with pitman arm
gm spring hangers
2" wheel spacers
spring perches
frame sleeves for shackle hangers

I have all the the stock stuff out. Start cuttin this week. Ill post pics tomorrow

jcasey10 07-28-2011 10:19 AM

Sounds like a hell of a project, I'm curious to see how it goes

Wildcat 07-28-2011 12:40 PM

Looking forward to seeing how this goes. I was surprised that there aren't any "kits" out there to do this. Good luck to you. Sounds like you got some good components so far. Are you upgrading the shafts and U-Joints from the bronco?

rs182 08-02-2011 02:46 AM

Update! Finally got around to working on the truck this weekend. I got all the Ifs crap cut off, axle prepped and fab up the new cross member and spring hanger. I did make a few minor changes as I was working.

The springs are on a 36.5 centers so I can bolt a super duty axle up later and the width works perfect for the dodge frame.

I ended up ordering a rough country 2" chevy lift I found on Ebay for $400 new shipped to my door. Came with shocks, leafs, poly bushings, 2 " blocks, and U bolts. The only thing I cant use is the rear U bolts since GM corporate 14 is 3.25" OD and the 9.25 is 3.5"OD Money well spent I hope.

I am not sure how steering will work out I may have to do cross over. Ill see how it looks after the axle is mounted.

He are a few pics of progress so far

cross member /spring hanger

test fit

I left the factory cross member in until the replacement was welded in to insure everything stays straight.

More updates soon

Stangshcky12 08-02-2011 12:35 PM

Looks pretty cool

rs182 11-10-2011 05:55 PM

UPDATE sorry for the delay guy. I have been super busy. The truck has been running solid axle since august. It of course took about twice as much time as I thought and cost twice as much too. Projects like this seem to work out like that. Here are more pics of the SAS for your enjoyment.
Building custom steering linkage
Axle installed
On the ground

rs182 11-10-2011 05:57 PM

A few weeks ago I pulled my rear axle down to install 4.56 gears and found my trac lock had come apart and trashed my housing. My buddy just happened to have a gm 14 bolt with 4.56 and a Detroit locker laying around so I thought it would be a good time to upgrade.
I thought it would be a simple swap and just swap my D44 outers to gm 3/4 8 lug to take care of the front..........
Well the front was easy.....
After a few quick measurements I quickly saw that a disc brake conversion was a must! No way in hell it was going to fit with the drums. You can see how close it was to not fitting.
Here is with the drum removed

Once I got the disk brake on I had to tackle the drive flange issue. I planned on using the napa 1/2 ton to 1 ton conversion U joint but dodge uses a odd size so I had to do some custom drive shaft work
I tied up the ABS sensor and took it out for a spin.
Thats when I said oh **** no speedo oops

I didnt realize that the PCM used the ABS/tone ring for a VSS. I pondered for a few days and started looking at tone rings that would fit a 14bolt. Turns out a dana 70 is damn close so the truck went back on the lift and out came the carrier and on the lathe it went

soon I was in business

rs182 11-10-2011 05:58 PM

I got the carrier installed and double checked the back lash
I built A mount into the diff cover to hold the sensor
I got it all wrapped up last night and drove it around this morning. I am happy to report that all is well and she is much happier with 4.56's than she was with 3.55's lol.
My speed is off my about 5mph. I will try and flash the computer Monday if I get time. Shouldnt be a big deal.

I also ordered a vanity plane that says "mutt" hahaha

The truck is now on 16x10 procomp alloys and 305/70/16's Ill try and grab a pic in the next few days

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