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Jay's SAS build thread


SQRLPWR

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So, I've stripped down the axle housing of all of it's components and it turns out the axles are done - just too much corrosion on the ears to be worth using.

I've had major problems sourcing new axles from Ford - the dealers I've called have been unable to lookup the part numbers for anything before 1980 as it's on microfiche, and their machines either don't work or were junked.

I even had a web-chat with Ford and they've pointed me in the direction of a specialist. My hope is if I can get the part numbers then the dealers can order them.

I'll keep trying, but there's going to be a point where I'll HAVE to order some from the Rock Auto, and they ain't cheap!! BUT, the upside is, the kit is 4340 Chrome-Moly :):):)

Anyways.....this is exciting, and quite honestly freaking scary as **** !!!

 

 

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So it me or if you go with big tires, its gonna cost you more to replace the axles than to get a newer axle cause that stuff is kinda kk and hard to order?

Plan isn't to go crazy with massive tires, 33's maybe a little bigger - TBH honest I've not thought that far ahead yet LOL - but you're right. The Rock Auto axles are warranted for 5 year up to 35's. IDK what stock D44 axles are rated for.

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Keep looking, you'll find the part numbers or some non-chrome alloy axles at better prices.  Did you try LMC Truck and some of those places yet?  Ford Forums?

I've had good luck lately sorting part numbers for various Scout and GM Square Body stuff.  It doesn't always come the first try!

Based on what I've read and experience with my former GM 10 Bolt axle, which shares many parts with the Dana 44, 33"s survive well under a light truck and small engine!  35"s would survive under your truck as well. 

 

And that axle looks dead sexy under that X!  You should be really happy when it's done!

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So I didn't here back from RadCo - so I've ordered a complete set of OEM shafts, ujoints and slingers from the Bronco Graveyard.

All my other parts came in this week, so I've got almost enough to rebuild the axle once I knocked all the surface rust and painted what's left.

All that's left to think about is;

Wheels - need some :)

Shocks - need some also

Springs - I took a chance and ordered F250 spring/shock mounts, so I need to figure out what will fit and lengths

 

IMG_20150923_163457.thumb.jpg.e01ba9f3c3

 

Drag link - I've got a new bronco link which is not adjustable, so I doubt it'll be the right length

 

Track Bar - I have the Bronco TB. Need to figure out length and mount

Track Bar mount - I guess I can only really deal with that once the axle is under the X and I have measurements

Drive Shafts?

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More rust cleaning and painting....

IMG_20150924_093211.thumb.jpg.a940b3861a 
 
And to my next decision / problem - corroded radius arm studs.
It took my 650 ft/lbs impact wrench many many attempts to remove the nuts and old bushings, but I'm not sure if they're gonna be safe. If not, then I'm kinda stuck for now.
Opinions/thoughts?
 
IMG_20150924_093151.thumb.jpg.188b9e942a
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yup, that's my fear right now. I would imagine IF I were able to source another set locally, that they would be in similar shape.

I thought of maybe cutting the studs off, and tapping new holes for new studs.

Or, cut and extend - but that's more work that I'm trying to avoid LOL

http://www.pirate4x4.com/forum/ford/912061-lets-see-your-home-made-radius-arms.html#post11907592

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