Well I figured I'd finally start this thread up. It's been almost 7 months since I bought the axles, so needless to say I could be making a run at RedRanger4.0's never-ending project type length.

I finally picked up a DD (my 07) so now I can tear apart the 99 without fear. The axles have been purchased. I've been researching this for damn near 4 full months now. I think I'm finally starting to get where I want everything to be. Although a lot can change once things start getting assembled.

I'm going into this with very little 1st hand knowledge about suspension so for those of you who think that you just don't know enough about trucks/vehicles to do a project like this, hopefully you can find this as some sort of inspiration. I'm going to document the hell out of this thing and their definitely will be loads of pictures along the way.

Anyway, back to the starting point. A Dana 44 and a Ford 9" out of a 1979 Ford Bronco. Yes I have the cast wedges. We'll see how that goes as the project moves along. That was probably a rookie mistake, but I think I can use the radius arm setup just fine using WHITE RHINO's ride as a example of sorts(he's got Ranger over on Pirate).

Anyway, here's my project parts lists so far (and this is bound to be much longer when it's all said and done, * means it's already purchased):

Tires and Wheels
*35x14.5x15 Interco Boggers
*15x10 ProComp RockCrawler Xtreme Steel Series 97 Wheels
*15" Staun Internal Beadlocks

Dana 44 Parts
*5.13 Gears
*Detroit Locker
*Dedenbear Knuckles
*Solid D44 Cover
*Rebuild of the outer stuff completely (hubs, rotors, spindles, etc.)

Ford 9" Parts
*5.13 Gears
*ARB Locker (35 Spline)
*ARB Compressor
*35 Spline Moser Axles
*9" Master Overhaul Kit

Front Suspension
Stock Radius Arms Extended 12" (Not totally sure on extension length yet)
FOA Coilovers (Haven't figured out travel yet)
Trac Bar

Steering
Hi-Steer Kit
Tie Rod Ends
Haven't looked into Steering Box yet

Rear Suspension
FOA Coilvers (Not sure on travel here either)
4-Link

Other Projects
Fuel Cell (to make room for the 4-Link)
Interior Cage
Racing Seats with 4 or 5 point Harness

That pretty much covers everything so far. I will post up a completed part list of everything I have once it's all bought. I want to make sure to keep really good records of everything to just help others out if they want it.

Some notes about the parts. For now I'm going to use the stock axles in the 44 simple because no point in spending the $500 extra for new Chromoly axles if you don't need to. The 9" is getting them because it doesn't come with 35 Spline Axles stock so if you want a 35 Spline locker, you need to get 35 Spline Axles. I went with the ARB out in back so I can still drive it on the road if I want to take it somewhere not on a trailer.

Project Status so far

Hiatus (sure most of you figured that out already). I'm still working on the damn ARB locker and getting my bender operational. With summer rolling around, I should be able to get this project rolling again. I'd like to say I'll get the axles completed this summer, but I'm not making promises anymore.

 

sounds like it will be a beast!

 

Nice! Done yet? lol

 

Hey bro, just a tip for ya. I buy a lot of stuff from www.rockauto.com. They carry Dana/Spicer balljoints, etc and have very good prices. Most of the time even with shipping they're cheaper than your local parts stores. Plus they have a much better selection.

 

Spindles usually have to be beaten off, but you need to sacrifice a pair of spindle nuts.

Thread the nuts onto the spindle (two of them) so they meet up -- don't put the lock ring on. Then beat that puppy from all sides like it was a red headed stepchild. Do all your beating on the spindle nuts and not the spindle surface.

That's what I had to do with mine. Works great. The nuts will be dented and nicked when you're done but it's good to use new spindle nuts when you rebuild anyway and they're not that expensive.

 

Good luck! Cant wait to see the finished product.

 

I will never be dethroned.

 

sounds like what im planning in a few months/years

 

You going to have it done by Alumni Run at Skanee in July? You should def show up. It will be a blast. Plus I'd like to see it up close when your finished.

 

I highly doubt it. Next Alumni Run would be much more likely. There is just too much stuff I don't know to hammer it out in 6 months I think.

 

sounds wicked!

 

They make one with a threaded end for a bolt, just thread it onto the spindle then thread the bolt into the end and the bolt pushes on the axle shaft and forces the spindle off.

 

Sooo... cool pictures, and uhh...

done yet? :-) -laughs-


Sounds awesome, SAS is the way to go! :-)

 

Yeah yeah... I'll have some pictures in a week or 2. Like I said I'm going on vacation this in 2 days and I'll be gone for 6 days somewhere a hell of a lot warmer then here.

I'm gone from Friday to Friday so I'm hoping I can get the 44 torn apart next weekend and snap some pictures. And then the credit card will learn to hate me while the credit card company will learn to love me. Haha...

 

Small update... pictures in a day or 2 (although they won't be anything special).

Successfully got the Dana 44 disassembled (except the pumpkin). Spindles appear to be a decent shape but I'll probably be replacing most everything else. And for anyone who is curious I simply used a $12 3 prong gear puller (picked it up at Northern Tool) to get the spindles off. Re-threaded the nut and put the prongs on it and twisted with the center bolt resting on the axle shaft. I didn't even have to use a wrench on the end of the bolt, did it all by hand, and the spindles slid right off, so they weren't nearly as stuck as they appeared. Apparently just needed to have force applied in the right spot.

The order has been placed for the Dedenbear Knuckles (through Rockstomper.com) so they will hopefully arrive in week or 2.

Like I said, I'll snap some pics of the disassembly tomorrow or Tuesday just so I can prove I'm not just sittin' on my ***. Haha...

 

I didn't have any problems at all removing my spindles from my D44... that's weird. Good luck with this! I'll be watching closely. The thing holding me back more than anything though is money... lol.

 

badass!

keep us up to date!

i need to get my SAS project in gear and make it like the 4th SAS in progress thread

 

more like 10th! and i know one that will finish before most of them and its not even posted! haha

mine is still kinda active but i dont think anyone looks at it.

looks good man, glad you got that stupid spindle off. now you are ready for the fun stuff.

 

i probably wont post much till im done..

i'll be too lazy to take pics of all the steps, i can see
1-parts
2-hang ups
3-done

of course i say that now


i know of one thats not posted, and i'll be one of the first if not THE first one on here to see it (besides him)

 

Here's the pics. Just snapped a few pictures as was heading out to work this morning of the various crap lying around the garage now. Like I said... nothing really all that exciting. Just some rusted old parts.

One question I have that is probably a stupid one, is what are the bolts in the knuckle called? They aren't wheel studs as well are they? I mean the actual studs on this are coming from the hub / rotor assembly. So I wouldn't think the ones on the knuckle / holding the spindle on would also be called studs. I looked over the couple exploded views I have an neither lists what they are called. Just curious if they have a proper name. Like Spindle bolts or something.

9" Disassembly.


1 Hub Disassembled from the Dana 44.


Dana 44 Spindles.


Dana 44 Caliper Brackets.


Hubs, Rotors, Dust Shields from the Dana 44 as well as other parts and dirt. Haha...


Finally, the Dana 44 most stripped down.

 

Spindle studs is the correct term. If you need new ones Jeffsbroncograveyard sells them.

Just FYI, www.rockauto.com has really good prices on rebuild parts and they are one of the only places that I've found which sell premium Spicer and Moog parts.

 

I bought most of my rebuild parts from Partsmike.com, mike has really good prices.

 

I've looked at his page before and it never seems like he has anything. Am I missing something? Do you need to call to determine what he has or what?

Plus it seems like most of the stuff under the Dana 44 section for the Jeep 44. The parts look way different.