SAS costs, time and tools - Ford Bronco Forum
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post #1 of 21 (permalink) Old 03-04-2003, 02:15 PM Thread Starter
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SAS costs, time and tools

again copyed from dogonmot

I have gotten tons of e-mail and read a million posts asking about the costs of doing a Dana 44 axle swap. I have a really good shop with more tools then most and this is what it cost me. I did more then alot of people do and the amout of money and time spent reflects it but so does the end result.

There's more than one way to skin a cat. I'm not saying this is the only way to do it but it's what made sence to me for the type of wheeling I do.

If you would like to see some pic's of my swap visit my Super Ford page. There is a link in my signature section.

I hope this helps.

-Scott

SAS Costs
100.00 78 Dana 44 with radius arms and brackets (sweetheart deal - usually $200 - $400)
25.00 Radius arm caps with out shock mount (2)
135.00 78 6" Super Lift springs
32.00 7 Degree "C" bushings
18.00 Radius arm bushings
320.00 RS 9000 X shocks (4)
30.00 ProComp steering stablizer
36.00 Beard limiting straps (2)
30.00 78 upper spring buckets
30.00 78 lower spring buckets
25.00 Spindle studs (10)
60.00 Misc. hardware
44.00 F250 upper shock mounts (4)
110.00 Chebby tie rod and drag link ends (2 & 2)
10.00 Jam nuts for Chebby tie rod ends (2)
100.00 D.O.M. tube for tie rod and drag link
40.00 Axle U-joints (2)
42.00 Upper ball joints (2)
41.00 Lower ball joints (2)
60.00 Inner & outer wheel bearings (2 & 2)
10.00 Wheel bearing seals (2)
64.00 Loaded caliper (2)
62.00 Rotor with hub & lugs (2)
10.00 Break hardware kit
50.00 D.O.M. tube for track bar and brace
180.00 Heim joints for track bar and brace (4)
20.00 Steel used for track bar mount and brace
50.00 Paint, oil, RTV, grease, ect.
160.00 4.56:1 Gears
90.00 Master install kit
50.00 Pinion yoke and U-bolts
55.00 3.92:1 and up empty carrier
22.00 Drive line U joint
30.00 Cosmo & Cam alignment shims
50.00 “Pro” done alignment
2191.00 Total

Reused TTB parts
·Dropped pitman arm
·Warn Hubs
·Extended break line (fabbed new retaining brackets)
·LockRight
·PowerTrax cross shaft

Special tools needed
·7 degree tapered reamer ($65.00)
·7/8" 18 pitch right hand tap ($78.00)
·7/8" 18 pitch left hand tap ($148.00)
·3/4" 16 pitch left hand tap ($95.00)

Tools used to do the job
·Air tools (1/2" impact gun, 3/8" wrench, 90 degree drill, cut off wheel, die grinder, air hammer)
·Electric tools (3/8" & 1/2" drill, grinder, saw-zal, bench grinder, drill press)
·Shop tools (20 ton press, vise, anvil, jacks, jack stands)
·Metal working tools (lathe, MillerMatic 210, Oxy torch)
·Hand tools (all the standard stuff, Dana 44 hub tool, tap & die set, good set of drill bits and a bit sharpener)

Estimated hours to complete work
10 Gathering of parts (over 2 weeks)
8 Cleaning and painting of parts
5 Complete rebuild of axle
2 Build steering and track bar
4 Fabrication
6 Remove TTB, front suspension & prep frame (2 people)
4 Install spring buckets, radius arm brackets, shock mounts & track bar bracket
4 Install axle, break lines, shocks, steering & drive line (2 people)
2 On road testing and tweaking
45 Total Man Hours

Just a final statment...It's worth all the time and every penny.

--------------
1994 Bronco
http://www.superford.org/registry/index.php?vID=211

Ford Senior Master Technician

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post #2 of 21 (permalink) Old 11-22-2004, 10:55 PM
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Its nice to have the following for rebuiding a Dana HD-44

I can't remember the sockets offhand.

7/8 and 1 1/8 impact sockets, I cant remember what I used for the pinion nut except I had to borrow one. Buy a standard impact socket set, because you dont want to use hand sockets with a impact.

Balljoint press, and air chistel
Its harder to get balljoints off on a HD-44 with the swing arm, used a
chistel with three points /\/\/\

1/2 drive rachet and breaker bar (I like Sears because they have a better handle, I hate knurled handles) along with a locknut socket.

Set of picks from Snap On, Not for picking your nose you idiot
Need to use to remove snap ring and assembly

1/2 drive impact to get rusted bolts off

Need an Air Compressor if you dont have one, I have a 175 PSI

Pry bars

Big Ass Screwdriver

Set of hex sockets (I can't remember what size, 1/8th or 5/16th.
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post #3 of 21 (permalink) Old 11-23-2004, 08:08 AM
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How much different is the cost of doing a solid dana 60? What different parts are needed?

Thanks,

Kyle
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post #4 of 21 (permalink) Old 11-23-2004, 08:23 AM Thread Starter
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damn talk about an old post.....there should be another post like this but with the 60info. I beleive dogonmut posted it.

take the price of all the 44 stuff and double it. everything for the 60 is more expensive incluing the initial cost of buying the 60.

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post #5 of 21 (permalink) Old 11-23-2004, 12:26 PM
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YES PLEASE MAKE THIS A STICKY!

Mine is in Excel format, and doesnt cut and paste to html well.
I will post it later when I am not feeling like a lazy ass.

My final cost for my entire project (At the time it was "completed") was
$3497.20.
But that did include tires, and a few other optional purchases.

"For me, it is far better to grasp the Universe as it really is than to persist in delusion, however satisfying and reassuring."
Carl Sagan PH.D.
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post #6 of 21 (permalink) Old 11-23-2004, 10:54 PM
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out of pocket...$420 or so. initially.
8lug swap,gears swap,carrier....all traded parts.
upgraded dom steering another $200 ish.
=pretty damn cheap.
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post #7 of 21 (permalink) Old 11-23-2004, 11:10 PM
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how much is that in american dollars?

i wouldn't go so far as saying everything for a 60 is double, but they are more expensive. then there is the whole issue of how much you'd have to pay to make a 44 comparable to a 60....and that is another story that doesn't belong in this thread.

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post #8 of 21 (permalink) Old 11-24-2004, 11:07 AM
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Here's some more old info. I'll see if I can find my 60 info.

--------------------------------------------------------------------------

10.25 / Dana 44 8 lug conversion

Much like my front-end swap, there are a million ways to skin a cat and this is only one of them. It’s what made sense to me for the wheelin’ I do and the way I run my rig. It’s also part of the larger, over all plan I have for the rig. This is merely a cost break down to give you an idea of what it took me as well as the time I spent working on the set up.

Both of these swaps are really strait forward. The 8-lug conversion is just pulling your spindles off, replacing the caliper bracket, and doing a break job…with bigger parts of course.

As far the 10.25, it to is about as simple as it gets. That project does require welding but if you are really thinking of doing this you probably have the means.

I hope this helps someone considering either or both swaps.

Good luck,

-Scott

- Sterling 10.25 Swap -
$375.00 Complete 95 Sterling 10.25 salvage axle (Less then 40,000 miles on the donor truck. Awesome! )
$265.00 4.56:1 gears (US Gear)
$150.00 Over haul kit (not a master install)
$35.00 Randy’s Ring and Pinion Super Shim Carrier shim kit
$45.00 1330 pinion yoke and strap kit (Spicer)
$20.00 1330 U joint (Spicer)
$350.00 Lock Right (Power Tracks)
$75.00 Pro done drive line work. (removed 1.75”)
$32.00 16 lug nuts (OEM)
$45.00 gear oil, RTV, Grease, etc.
$52.00 5/8 U bolts (Valley Spring)
$1445.00 Total

*I did not rebuild the breaks. The ones it came with were in perfect shape. If I had, it would have cost about $75.00 more.

- 8 lug dual piston caliper Dana 44 front end conversion -
$60.00 1978 F250 hubs (salvage)
$70.00 New rotors (2) (Auto Zone)
$20.00 1978 outer caliper (2) (salvage)
$90.00 remanufactured caliper (2)(NAPA)
$30.00 break hardware (Auto Zone)
$45.00 pads (Checker)
$40.00 1978 dual piston caliper bracket (2) (salvage)
$45.00 outer wheel bearing (2)(Auto Zone)
$32.00 inner wheel bearings (2) (Auto Zone)
$6.00 inner wheel bearing seals (2) (Auto Zone)
$32.00 16 lug bolts(NAPA)
$24.00 16 lug nuts (NAPA)
$84.00 1994 F250 Master Cylinder (Auto Zone)
$7.00 grease, break fluid, etc.
$585.00 total

Tools used:
•Pneumatic – ½” impact gun, 3/8 ratchet
•Electric – 4.5” angle grinder
•Fab - MIG welder
•Specitiality – the usual stuff to set up gears, Dana 44 hub tool
•Shop – 20 ton press, vice, hand tools (socket, wrenches, drivers, etc.), Jacks (2), tall jack stands (2)

Times for 10.25 swap:
•6 hours to locate parts over a 4 month span
•2 hours to clean and prep parts
•4 hours to regear 10.25
•1 hour to remove 8.8 (2 people)
•1 hour fab work (cut off and reweld spring perches)
•2 hours install 10.25 under truck (2 people)
16 hours total

Times for 8 lug conversion:
•6 hours over 4 months to locate parts
•1 hour clean and prep salvage parts
•1 hour remove 5 lug set up, clean reused parts
•1 hour pack new bearings, press in new races and lugs
•2.5 hours install new parts and master cylinder
11.5 hours total

Rear end parts reused:
•Brake line
•Electrical wiring to wheel speed sensor
*I got lucky. My 10.25 came with E-brake cables and they were the correct length to tie into the same bracket that the 8.8 used.

5 lug parts reused:
•Warn hubs
•Banjo bolts
•Cosmo alignment shims
•Brake lines
•Knuckles
•Ball joints
*The last 2 obviously did not have to be removed to do the swap.
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post #9 of 21 (permalink) Old 11-24-2004, 11:49 AM
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Here's the 60 costs. This was the costs to get it and rebuild it. There's no suspension mod. costs in this break down. This is axle only. I got a smokin' deal on the axle to start with.

PART PRICE VENDOR
78 Dana 60 300 Friend
4.56 Gears 225 Randy's
Rebuild kit 120 4WP
ARB 675 Gears4Less
ARB compressor 85 Gears4Less
Axle U joint 806X 80 4Wheelers
King pin rebuild kit 80 Randy's
Axle shafts 385 Randy's
Cross over arm & studs 140 WFO/Chevy
Rotors 110 AutoZone
Calipars & pads 220 Car Quest
Brake lines 110 4Wheel Parts
Brake hardware 25 Car Quest
wheel studs 75 Car Quest
Wheel bearings 110 AutoZone
Wheel seals 27 AutoZone
Locking hubs 100 ebay
Spindle nuts 60 Car Quest
Spindle parts 50 Parts Mike
Pinion yoke & straps 65 WFO
1350/1330 U joint 35 4WP
Inner axle seals 25 Parts Mike
DOM tube 200 in stock
Rod ends (steering) 102 Checker
Expendables 100 Misc.
Misc. crap 200 god only knows

Totals 3704
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post #10 of 21 (permalink) Old 12-10-2004, 07:18 PM
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just a quick post mine cost 5500 that includes gears tires rear locker duff rad arms and bullet proof steering
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post #11 of 21 (permalink) Old 12-31-2005, 09:03 PM
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My SAS swap costs

1978 Diff, radius arms, complete 200.00
9" skyjacker springs for 70's ford truck 159.00
fa400 drop pitman arm 49.00
4 - 3/4 shank 3/4 hole heims 78.00
22 ft 1 inch .156 wall dom 100.00
3.5 inch fabtech rear blocks 35.00
pro comp 3 in 1 brake line kit 72.00 (2 front, 1 rear)
3/4 tap for DOM 9.00
3/4 bit for drop pitman and knuckles 11.00
2 - brake calipers 18.00 ea
1 - set pads 15.00
2 - axle seals 2.59 ea
2 - outer bearings 5.99 ea
2 - inner bearings 6.99 ea
1- Rock krawler 4 inch track bar drop mount free (used)
2- sway bar disconnect links free (used)
2- 70's radius arm mounts 20.00 salvage yard
2- cases beverage
1- carton cigarettes
1- new wig for hair I pulled out
1- set dentures for teeth I ground off

22 hours work

well worth the time and effort
just drove it home tonight, 70 mph and no problems



p.s. had to flip rear shackles to provide additional lift for rear of BRonco.. total of 7" rear lift 9" front

oh and ford track bar works with the rock krawler's track bar drop mount.. bushings a little to flexible for 9" lift.

Silence
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post #12 of 21 (permalink) Old 05-15-2006, 12:48 AM
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I am going to post up my costs here as much for me as anyone else. I will probably edit along the way. Here goes:

300 - Dana 44 complete, 1 TRE, 1 set brake pads, 2 sets radius arms w/caps, 3.55 gears and 4.56 gears, 1 pair rad. arm brackets
185 - 6" super flex coils inc. shipping (my old springs were not gonna work)
138.88 - tie rod center link, drag link, and one sleeve (I got a 10% break)
130 - Superlift Adjustable Track bar (don't remember what shipping was)
100? - brake lines and adapters (still need to buy)
100? - set gears
57 - cage 14" travel shocks - set of 4
40? - one TRE
33.89 - one new ball joint and one can of black spray paint.
27 - poly 7 degree c bushings and rad arm bushings
20? - stock pitman arm from someone on here - inc. shipping
19.45 - one sleeve for steering inc. tax
10??? - one can primer and two cans paint from home depot
0 - hardware, bits, taps, some borrowed tools, etc. from work
0 - help from friends welding frame up, borrowed torch, borrowed drill
0 - track bar bracket from a buddy in my club

Unrelated stuff:

220 - 4.56 gears and true trac locker for 8.8
400 - used 35" mudkings
60 - mount and balance tires
?? - shackle flip and whatever else I will need to get the rear end level

Still have TTB to sell, and a drop pitman arm.

so depending on what all you include I could have from 1000ish to 2000 ish in it.
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post #13 of 21 (permalink) Old 04-25-2008, 06:18 AM
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79 60 with new joints,rotors and gm calipers 1500
35 spline allows 250
mm lockouts 135
detroit locker 495
sierra 4:56's and install kit 225
1350 yoke 65
ballistic fab raised track bar mount 29
WFO track bar 185
WFO high steer arms 220
I used my dom drag link and tie rod off my 44 high steer
wedges from duffs 85(should have went with cage arms)
Piece of mind that I wont pop a joint or brake a stub shaft,priceless
44 are good axles but I got tired (and good) at changing shafts and joints. It aint cheap neither. I had better luck with the spicer then with chromoly stuff. Seems Like the spicer stuff would bent and stretch others would explode
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post #14 of 21 (permalink) Old 03-26-2009, 09:17 PM
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This is the original cost for me, prior to any modifications done AFTER original SAS completion.

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post #15 of 21 (permalink) Old 05-21-2009, 10:08 PM
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SAS Help!

Hey i am asking help on getting and purchasing a Dana 60(D60) and a Rear Sterling 10.25 rear axles. Where can i get these items at and how much would it cost to have it installed by a offroad shop? Would a junk yard be the better place too look for these or a remanufactured unit from broncograveyard.com?
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post #16 of 21 (permalink) Old 05-31-2009, 01:02 PM
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drop brackets?

does anyone have the axle drop brackets and radius arms for a ttb axle? the only reason im posting here is hopefully to find someone who sas'd their truck and no longer need the parts. I have a sterling rear axle for a possible partial trade on the brackets. Its an 89 bronco with a 4 inch lift. thanks again.
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post #17 of 21 (permalink) Old 05-31-2009, 04:14 PM
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Quote:
Originally Posted by 89Skanky View Post
does anyone have the axle drop brackets and radius arms for a ttb axle? the only reason im posting here is hopefully to find someone who sas'd their truck and no longer need the parts. I have a sterling rear axle for a possible partial trade on the brackets. Its an 89 bronco with a 4 inch lift. thanks again.
pm sent
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post #18 of 21 (permalink) Old 07-09-2009, 08:46 PM
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Quote:
Originally Posted by Broncoguy2009 View Post
Hey i am asking help on getting and purchasing a Dana 60(D60) and a Rear Sterling 10.25 rear axles. Where can i get these items at and how much would it cost to have it installed by a offroad shop? Would a junk yard be the better place too look for these or a remanufactured unit from broncograveyard.com?
Quote:
Originally Posted by 89Skanky View Post
does anyone have the axle drop brackets and radius arms for a ttb axle? the only reason im posting here is hopefully to find someone who sas'd their truck and no longer need the parts. I have a sterling rear axle for a possible partial trade on the brackets. Its an 89 bronco with a 4 inch lift. thanks again.

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post #19 of 21 (permalink) Old 08-20-2009, 05:31 PM
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i guess i forgot to post my info. it was around 10 grand. one ton, custom front suspension, geared, locked (both ends), new tires. i'll link the cost sheet later. it's got break downs for the major groups of stuff.

95: 351w, E4OD, BW1356, D60, 10.25, ARB, detroit, 5.13, H1's, 38" boggers
http://www.supermotors.org/vehicles/...il.php?id=9014
'93 F250 7.3 turbo, ZF5, 2wd, excab, long bed.
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post #20 of 21 (permalink) Old 12-02-2009, 07:22 PM
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rad arm brackets

putting a sas in my 92 f-150 and putting six inch coils under it can i reuse my drop down rad arm brackets from my ttb lift and set them back farther on the frame
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