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-   -   D44, coil sas for me. (https://www.fullsizebronco.com/forum/29-solid-axle-swaps/219162-d44-coil-sas-me.html)

zippome 03-15-2013 11:39 PM

D44, coil sas for me.
 
So I'm just about done with my SAS and I have failed to make a build thread until now. But better late than never I guess.

First of all I would like to say that I tried to use as many stock parts as I could. Here is my parts list.

Axle - D44 out of a 79 Bronco, 4:56 gearing, eaton locker, new manual locking hubs, and a heavy duty diff cover from ruff stuff.
Brakes - Stock 79
Brake lines - The 88 extended ones from JBG.
Drive shaft - stock 88 that I got extended
upper coil buckets - stock 79
shock towers - stock 85-93 f250
radius arms - stock 79
radius arms brackets - stock 79
track bar - superlift extended 79
track bar mount - ruff stuff
coils - 4" lift 79
shocks - pro comp 16 - 26
tre and drag link - DOM
pitman arm - I used the drop one that I had from when I did my 6" lift.
new steering gear box because I needed one.

Here is a before pic. I had already done a 6" lift with the TTB.
http://i1126.photobucket.com/albums/...00523-1623.jpg

Here is my new to me axle.
http://i1126.photobucket.com/albums/...ps4aaa01dc.jpg

I had to bow out at this point, and I took the axle to a shop to have it re-built. I don't have to means of knowledge to do it myself.

So of course the first thing I did was rip everything out!
http://i1126.photobucket.com/albums/...ps4bed5f90.jpg

I didn't take a whole lot of pics so I'm going to apologize for that. After I ripped it all out and cleaned it up I thought that the most important thing to do first would be the coil buckets.

The drivers side was a PITA. I think that was the main thing I learned from all of this was that everything on the drivers side sucks. But like a lot of people I wanted to move the coil buckets forward an inch for better fit with bigger tires. that's the whole reason that I used the 79 coil buckets, you can use the stock 88(or whatever year you have) if you don't want to move them forward. So to move the drivers side forward I had to notch out the bottom and move the bolt locations.
http://i1126.photobucket.com/albums/...psd7d5b48c.jpg

the passenger side went in like a breeze.
http://i1126.photobucket.com/albums/...pscab2547c.jpg

After that I got to hang the axle from the coils and then figure out placement for the radius arm brackets.
I decided to use the stock 79 brackets because I'm only planning on doing a 4"-6" lift.
http://i1126.photobucket.com/albums/...ps2274fb9e.jpg

I located the track bar mount just forward of the coil bucket. I didn't take a pic of it yet but you can see the spot that I cleared off for welding.
http://i1126.photobucket.com/albums/...ps92823b80.jpg

To install the tre and drag link I had to use a reamer which was fun.
I also had to cut the front part of the cross member and I had to remove the old power steering fluid cooler and put in a new one that I picked up at auto zone for $20. It was actually a tranny cooler but it will work.
http://i1126.photobucket.com/albums/...psb5a90465.jpg

I got to make a trip down to Driven Auto to pick up some parts, bronco heaven.
http://i1126.photobucket.com/albums/...ps0fd62d12.jpg

It's on it's own weight right now and I just drove it on the freeway. After doing that I realize that I need to get a steering stabilizer and get a professional alignment. My redneck alignment is just a little bit off.
I also need to switch out the stock D44 yoke with the old TTB one so I can get my drive shaft u-bolt to fit.

81bronco44 03-16-2013 12:19 AM

About time :thumbup does this mean you might finally go on a trip with us az guys?


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zippome 03-16-2013 12:24 AM

that is exactly what that means!!!

zippome 03-16-2013 02:43 PM


PVTbronco 03-17-2013 03:47 PM

Wow, great build! I like how it isn't totally jacked up like most others. I'm guessing you're running 35"x12.5" right? Also, why did you have to cut the crossmember? Just so you know I will probably be pestering you more and more when i get close to doing mine hahaha.

zippome 03-17-2013 04:04 PM

Quote:

Originally Posted by PVTbronco (Post 3058672)
Wow, great build! I like how it isn't totally jacked up like most others. I'm guessing you're running 35"x12.5" right? Also, why did you have to cut the crossmember? Just so you know I will probably be pestering you more and more when i get close to doing mine hahaha.

That's fine, pester away. Yes I am running 35"x12.5". And I cut the cross member because otherwise the track bar would of hit it. If you move the axle forward more than I did you can get away with not cutting it. But that is a lot harder than just cutting the cross member.

PVTbronco 03-17-2013 04:22 PM

very nice. How much did it cost excluding the d44? if you don't mind me asking

zippome 03-17-2013 04:50 PM

well I got all of the stock 79 parts with the axle, so I had to buy

coils and the track bar - $379.47
DOM tre drag link - $389.01
F250 shock towers - $40
all new bushings about - $100
new hardware about - $50
power steering cooler - $20
shocks - $97.02
extended drive shaft - $100
total $1175.50

I think that should be it.

AUBronco 03-17-2013 06:10 PM

That looks great. Can you get some measurements for reference on the height. It would be interesting to see how it compares to a standard ttb lift.

Vannnce 03-17-2013 06:16 PM

howd you do your trac bar bracket? pictures of that would be awesome
As for your front yoke, i just used a conversion u joint, works great :shrug

zippome 03-17-2013 06:28 PM

Quote:

Originally Posted by AUBronco (Post 3058738)
That looks great. Can you get some measurements for reference on the height. It would be interesting to see how it compares to a standard ttb lift.

I had a 6" lift on the front with the TTB. I put a 4" lift on it with the SAS, and it is sitting about 1" lower in the front. That's with all stock 79 upper and lower coil buckets.

Quote:

Originally Posted by Vannnce (Post 3058740)
howd you do your trac bar bracket? pictures of that would be awesome
As for your front yoke, i just used a conversion u joint, works great :shrug

For the track bar mount I ordered mine from Ruff Stuff. LINK

http://i1126.photobucket.com/albums/...pscbcfc487.jpg
http://i1126.photobucket.com/albums/...psebd1661d.jpg
http://i1126.photobucket.com/albums/...ps5a07df77.jpg
http://i1126.photobucket.com/albums/...ps8ecc9024.jpg
http://i1126.photobucket.com/albums/...pse87621ed.jpg

yeah I was thinking about just using a conversion u-joint as well, but I was thinking that if I happen to be out on a trail somewhere and I break one it would be nice to have a very generic u-joint to make it easy to find a replacement.

BroncoVanner 03-17-2013 07:42 PM

Nice clean install, looks good!

zippome 03-17-2013 07:47 PM

Thanks! I was just trying to make it as simple as I could. I wasn't looking to go crazy with it. I just hated the ttb and had to get rid of it.

81bronco44 03-17-2013 08:40 PM

Zip your drive shaft should be fine I never got mine extended and were running the same lift


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zippome 03-18-2013 12:08 AM

cool, thanks

norfolkff05 03-20-2013 08:25 PM

good job man. hit any trails with it yet?

zippome 03-21-2013 04:21 AM

Thanks but no trails yet. I still need to swap out the yoke so I can attach my front drive shaft. I have just been busy the last few days. But as soon as I do I'll be going out.

Shadofax 03-23-2013 01:32 PM

looks good, you made the most of the parts you had and kept your swap very reasonable.

zippome 03-23-2013 03:12 PM

Quote:

Originally Posted by Shadofax (Post 3063104)
looks good, you made the most of the parts you had and kept your swap very reasonable.

Thanks, that's kinda what my plan was. I wanted it to look like it could of come sock that way. And with using a lot of stock parts it will be real easy and cheap to find replacements.

zippome 04-01-2013 03:03 AM

A little update. I did end up getting the drive shaft extended at Arizona Driveshaft. They did a great job and it cost me $100. I also decided to not swap out the yoke, all I did was get a stock 1 1/8 u-joint from the 88 and swap out the two caps to 1 1/16. fits perfect and if I do end up breaking one it won't be to hard to replace.


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