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Home/ Registry/ Ford/ Bronco/ 1992–1996/ “Shadofax”/ SAS-D44/D60FF swap supermotors.net/registry/628/23277

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SAS-D44/D60FF swap

From 1995 Ford Bronco “Shadofax” — documented by Mark Zoelch.

61 photos
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1995 Ford Bronco - Ford rear axle assembly, likely from a Bronco or similar truck, undergoing maintenance or modification. 1995 Ford Bronco - 3/8" custom caliper mounting plate by Jim H. 3/4T chevy disc brake setup. Plan to use exact same up front. 1995 Ford Bronco - Close-up view of the internal components of a vehicle's differential assembly. 1995 Ford Bronco - D60 toner from spicer, and new magnetic pickup from ford. Part numbers visible. 1995 Ford Bronco - Rear axle differential assembly with new Motorcraft parts laid out for installation. 1995 Ford Bronco - will be drilling a 13/16" hole up top to mount the VSS sensor. 1995 Ford Bronco - I did grind the diff for clearance. Ground my current 8.8 as well. Best I can measure there is 1/8" difference. 1995 Ford Bronco - This is a close-up view of a vehicle's brake system, focusing on the caliper and rotor assembly. 1995 Ford Bronco - A disassembled rear axle assembly, likely for a Ford Bronco, is supported by yellow jack stands in a garage. 1995 Ford Bronco - Rear axle assembly with brake caliper and brake lines, supported by a jack stand, likely undergoing modification or repair. 1995 Ford Bronco - Cut off old low hanging shock mount and fabbed these up out of 2x2 x .25" square tube. 1995 Ford Bronco - Detroit locker. I pulled this so we could press the toner ring on. 1995 Ford Bronco - shot of toner, with VSS sensor mounted up top. got the air gap between to apx. 1mm. 1995 Ford Bronco - another shot of sensor mounting 1995 Ford Bronco - D60 about ready, you can also see I welded on some new 1/4" flat plate to the spring perches after some grinding. They had rounded over the… 1995 Ford Bronco - Fabbed upper ubolt plate, 3/8" with 1/4" risers and offset 1" center hole for the ORD zero rate leaf (moves axle back 1"). 1995 Ford Bronco - overall shot. Shows clearance of shock mounts. 1995 Ford Bronco - VSS sensor mounted on top of diff. 1995 Ford Bronco - Now using Ujoint "ubolt" type connector (1330 series) instead of flange. 1995 Ford Bronco - Close-up view of the rear axle, driveshaft, and suspension components of a vehicle. 1995 Ford Bronco - close up of caliper. no more than 1/8" clearance to rim. 1995 Ford Bronco - Close-up of a Goodyear Wrangler off-road tire and black wheel. 1995 Ford Bronco - Right now, until front is converted, it's 8 lug rear, and 5 lug front. 1995 Ford Bronco - Speaking of front, here are many of the components that can be had "used". D44 78-79 housing, everything knuckle out is Chevy 3/4T, includi… 1995 Ford Bronco - Chevy Flat Tops. Going to use PartsMike.com stuff for high steer. 1995 Ford Bronco - E4OD Crossmember mod needed on pass side for Cage Radius Arms 1995 Ford Bronco - D44 cleaned up, ready for paint. this is my garage "staging" area. 1995 Ford Bronco - As part of the front SAS, I will be cutting the xmember, so the power steering tube needs to go, in favor of this itty bitty tranny cooler,… 1995 Ford Bronco - Hard to tell here, but the 8 lug 3/4T chevy hub and rotor is beefier, as evidenced by it weighing in at about 5 lbs. more than my 1/2T. TTB… 1995 Ford Bronco - again a bit tough to tell, but the big bearing chevy 44 spindle on the left uses a bigger inner bearing, this matches up with the larger di… 1995 Ford Bronco - Drivers inner D44 TTB top and the 3.25" longer '78 bottom. This is evidence the diff sits this more inward, which makes clearancing the xme… 1995 Ford Bronco - Front axle assembly, likely for a 4x4 vehicle, is black and appears to be recently serviced or painted. 1995 Ford Bronco - Vehicle axle and suspension parts are disassembled and arranged on the floor, likely for repair or modification. 1995 Ford Bronco - A close-up view of a suspension coil and shock assembly, likely undergoing maintenance or modification. 1995 Ford Bronco - A gray coil spring is mounted on a black axle assembly, likely for an off-road vehicle modification. 1995 Ford Bronco - Axle all ready to be put under 1995 Ford Bronco - TTB was taken out, upper coil mounts off, ready to begin putting new '78 solid D44 under truck. 1995 Ford Bronco - My old Rancho 4" coil used thicker coil rod, but was only 19" in length (compressed to 15.5"). Superflex coil is 26.5" and compressed to 21" 1995 Ford Bronco - This was the final design of the E4OD crossmember. Had to do this since the cage arms and mounting bracket are so long. 1995 Ford Bronco - locating axle under truck 1995 Ford Bronco - shot before coil was in, and caliper not mounted yet. I had already pre-ground the caliper and mounting bracket to clearance 15" wheels. 1995 Ford Bronco - caliper mounted. used a superlift stainless line meant for 8-12" lifted cheb. K20 truck, measures 31" 1995 Ford Bronco - cage radius arm and mounting bracket now sit about 3/4" inch in front of the e4OD xmember 1995 Ford Bronco - with weight on the coils, I had from what others had experieced, the same superflex bow problem. 1995 Ford Bronco - this is after the fix, wedge in bottom welded to the cup, made a new upper attaching strap, and added a U bolt retainer as well. 1995 Ford Bronco - all done, except for some tuning on all the work. 1995 Ford Bronco - go to subsection after SAS flex misc. pics for better shots. 1995 Ford Bronco - Track bar. Originally tried using the stock 78-79 bar. I redid that and now am running 1.125 DOM (.25 wall) tapped for 3/4" rod ends, secur… 1995 Ford Bronco - Detailed view of a vehicle's modified suspension and axle system. 1995 Ford Bronco - Detail shot of suspension parts, including a large coil spring and adjustable linkages. 1995 Ford Bronco - Custom suspension and axle work on a vehicle, focusing on off-road modifications. 1995 Ford Bronco - Front view of a 1995 Ford Bronco with added transmission coolers and a winch. 1995 Ford Bronco - Differential housing and suspension components are visible in this close-up shot. 1995 Ford Bronco - Two aftermarket wheels are displayed, one with a black center and the other with a polished finish. 1995 Ford Bronco - This document details the costs and parts breakdown for a SAS-D44/D60FF swap. 1995 Ford Bronco - I don't have the hi steer arms on at this time, clearance issues. This pic just for reference on hi steer and chevy flat tops. 1995 Ford Bronco - D44 8 lug outer...inner larger bearing race. 1995 Ford Bronco - This document contains detailed information, possibly related to vehicle specifications or performance data. 1995 Ford Bronco - Close-up view of differential gears and housing, showing a stamped part number. 1995 Ford Bronco - D60 rear with detroit and toner ring added 1995 Ford Bronco - 78-79 D44 front with the unusual "chip", but it's there for a purpose.