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D44 SAS

From 1996 Ford Bronco, documented by Jer Rizzuto.

89 photos
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1996 Ford Bronco - Finally got my axle. It is a Dana 44 Heavy Duty unit. It is Leaf Sprung. Keith Lawyer from CO got it off a 78 F250. 1996 Ford Bronco - All my thanks goes out to Keith_L. He is the man. 1996 Ford Bronco - The BOM is 610040 which means it came from a 1978 F250 "Part time". 1996 Ford Bronco - Just another shot. 1996 Ford Bronco - F150 donor truck for 5 lug outers, and steering. 1996 Ford Bronco - This is just a "before" shot 1996 Ford Bronco - Close-up of the underside/rear frame area of a vehicle showing a rusted metal bracket or crossmember with fresh weld repairs, positioned ab… 1996 Ford Bronco - Front view of a Ford SUV lifted on a garage floor with the front bumper removed, exposing the radiator, front axle, and a skid plate undern… 1996 Ford Bronco - Close-up underside view of a vehicle's front frame section showing a rusty, dirt-caked frame rail and mounting bracket, with a tire visible… 1996 Ford Bronco - Close-up of a rusty steel front suspension/frame bracket on the underside of a vehicle, with slotted mounting holes visible, next to a chun… 1996 Ford Bronco - Close-up of the front driver-side suspension and steering components on a dark-colored Ford Bronco, showing the wheel hub area, tie rod/rad… 1996 Ford Bronco - I modified Raf's original design a little and came up with an idea of what i want my Bronco to look like when it done. Notice the front lea… 1996 Ford Bronco - This is me grinding the frame after Keith cut off the bumper brackets with the plasma 1996 Ford Bronco - This is Keith using his favorite toy (Or at least one of them) 1996 Ford Bronco - A man in a yellow welding jacket, gloves, and a face shield kneels beside a jacked-up dark green Ford truck/SUV, welding on the front axle/… 1996 Ford Bronco - Underside view of a dark-colored Ford Bronco raised on a jack stand, showing the front suspension with a new red coil spring and white shoc… 1996 Ford Bronco - Underside view of a lifted 4x4 with a person using a grinder that throws sparks near the frame, showing coil springs, red-booted shocks, of… 1996 Ford Bronco - We used a high lift jack to support the front of the body while we plasma'ed off the body mounts. 1996 Ford Bronco - Underbody view of a black Ford SUV on jack stands, showing the front solid axle with a red coil spring, white shock absorber, differential… 1996 Ford Bronco - A man wearing safety glasses and a tan leather welding jacket over a gray shirt uses a red Hi-Lift jack braced against a wooden block to li… 1996 Ford Bronco - A man in a yellow welding jacket and dark face shield uses a cutting or welding tool near the front bumper area of a black Ford SUV, sendin… 1996 Ford Bronco - Keith getting ready to take off the sway bar mounts. 1996 Ford Bronco - A man in a yellow welding jacket, gloves, and red face shield lies on the garage floor welding or cutting under the front end of a black Fo… 1996 Ford Bronco - A person in yellow welding gear kneels beneath the front of a black Ford truck, using an angle grinder that throws orange sparks near the f… 1996 Ford Bronco - A person in a yellow welding jacket kneels and uses an angle grinder, throwing sparks, while working on the front axle/steering area of a F… 1996 Ford Bronco - A person in a tan welding jacket and heavy leather gloves uses an angle grinder or cutting tool on the front underside frame of a dark-colo… 1996 Ford Bronco - A person in a yellow welding jacket and gray Fox Sports Net t-shirt welds on the front frame area of a Ford truck, with bright sparks and w… 1996 Ford Bronco - Me holding the body mount from the drivers side. This is the only way to change body bushings, to bad I didnt have any replacements with me. 1996 Ford Bronco - Underside view of a Ford truck's front suspension and frame, showing a coil spring with red upper coils and a white-bodied shock absorber,… 1996 Ford Bronco - Underside view of a 4x4 vehicle's front suspension and axle showing a coil spring, white-bodied shock absorber with red boot, tie rod, and… 1996 Ford Bronco - Underside view of a Ford truck's frame and rear suspension, showing a rusty leaf spring shackle mount, welded frame section, and a white sh… 1996 Ford Bronco - Underside rear view of a lifted Ford Bronco showing the rear axle, drum brake backing plate, all-terrain tire, white shock absorber, and a… 1996 Ford Bronco - Me using the Plasma for the first time. 1996 Ford Bronco - A person wearing red-tinted safety glasses, a gray hooded sweatshirt, and work gloves grinds or welds metal on a steel workbench, sending a… 1996 Ford Bronco - A hand-fabricated sheet-metal box with visible weld seams and surface rust sits on a metal shelf or workbench, alongside a red-and-black we… 1996 Ford Bronco - A workbench in a garage holding fabricated steel brackets or metal parts, with a pair of worn leather work gloves, a red tool, and a blue p… 1996 Ford Bronco - Low front-suspension view of a black Ford Bronco raised off the ground, showing the coil spring, white shock absorbers, a red-booted steeri… 1996 Ford Bronco - Underside view of a vehicle's front frame section showing a welded steel bracket or frame horn with a mounting hole, positioned above a mud… 1996 Ford Bronco - Close-up underside view of a frame or crossmember with fresh weld beads joining reinforcement plates to a boxed steel bracket, surrounded b… 1996 Ford Bronco - Underside view of a vehicle frame section showing a boxed steel frame member with drilled holes and multiple weld beads. Fresh weld seams a… 1996 Ford Bronco - Front most spring hangers. Keith modified them a bit, and I cleaned them up with the grinder. 1996 Ford Bronco - A welded steel U-channel or box bracket fabrication sits on a dark workbench, with visible weld beads along its base. Surrounding tools inc… 1996 Ford Bronco - A welded steel channel-metal bracket or fabricated part sits on a dark metal workbench, surrounded by tools including locking pliers/clamps… 1996 Ford Bronco - The clean weld beads are Keith's. The ugly boogered up weld beads are mine. This was the first time in 13 years that I have used a welder s… 1996 Ford Bronco - A close-up of a welded steel joint showing multiple weld beads joining metal plates, resting on a wooden workbench with a hammer and shop r… 1996 Ford Bronco - This one I welded up, notice it is pretty ugly. Good thing Keith had plenty of grinders and grinding discs LOL! 1996 Ford Bronco - This is a pic of the first run of the front cross-member. We had to modify it a bit but at least you get an idea of what we made to start w… 1996 Ford Bronco - A homemade steel workbench sits against a metal garage-door wall, holding a yellow spirit level, a wooden-handled tool, and a metal tray; r… 1996 Ford Bronco - A metal welding or fabrication workbench in a garage holds a yellow spirit level, locking pliers, and a purple rag, with a black-lined tras… 1996 Ford Bronco - A metal fabrication workbench in a garage or shed, topped with a yellow bubble level, metal brackets, scrap steel pieces, and a rag. Below… 1996 Ford Bronco - Keith test fitting it. We had the fun of test fitting about 4 times over the weekend. Believe me Keith and I cussed at it everytime. 1996 Ford Bronco - Underside view of a Ford Bronco's front suspension showing a welded/fabricated steel bracket or crossmember, red Rancho RS5000 shock absorb… 1996 Ford Bronco - Close-up underside view of a fabricated steel bracket or mount welded to a frame crossmember, showing fresh weld beads and bare metal with… 1996 Ford Bronco - Underside view of a vehicle's front suspension being worked on, showing a coil spring, a white-bodied shock absorber with a red boot, and r… 1996 Ford Bronco - Underside front view of a Ford Bronco showing the front axle, a red-booted steering damper or shock, tubular crossmember, and radiator/cond… 1996 Ford Bronco - A man wearing black 'Mechanix' work gloves and a tan/yellow welding jacket works underneath the front end of a dark vehicle, viewing the fr… 1996 Ford Bronco - Front-end view of a Ford truck with the front bumper removed, showing the exposed frame horns, chrome grille with blue Ford oval, amber tur… 1996 Ford Bronco - Front-end view of a dark green Ford truck showing the chrome grille with Ford oval emblem, exposed radiator, and a bare welded steel tube b… 1996 Ford Bronco - Almost done, just weled the body mount back on. 1996 Ford Bronco - The other body mount and hanger 1996 Ford Bronco - Completed front end. 1996 Ford Bronco - Low-angle underside view of a dark-colored Ford Bronco showing a freshly fabricated/welded steel front frame bracket or mounting plate, wit… 1996 Ford Bronco - Underside view of a vehicle's rear frame and body area showing surface rust on the frame rail, a black plastic fender liner/heat shield, an… 1996 Ford Bronco - Close-up underside view of a welded square-tube receiver hitch mounted to a vehicle frame crossmember, showing fresh weld beads and surroun… 1996 Ford Bronco - Close-up of a fresh weld joining a new rectangular steel tube section to an existing frame rail, showing the cut end with visible internal… 1996 Ford Bronco - As you have seen Keith's idea was to box in the entire front frame horns with some good ol' steel (3"x6" IIRC). The x-member is 2"x4". This… 1996 Ford Bronco - We decided to get some ramp poser shots before my SAS is complete. As you can see this is pathetic. I have open/open diffs, 31's, and no sw… 1996 Ford Bronco - A black Ford Bronco full-size SUV viewed from the rear three-quarter left side, with a rear-mounted spare tire cover reading 'Ford Bronco'… 1996 Ford Bronco - A black 1990s Ford Bronco full-size SUV is driven front-first up a set of homemade steel ramps, with its front wheels elevated and undercar… 1996 Ford Bronco - Front 3/4 view of a green/tan 1990s Ford Bronco or F-series truck raised on metal ramps/stands, exposing the underside with visible front a… 1996 Ford Bronco - A black Ford Bronco full-size SUV parked on a homemade wooden ramp/service platform, viewed from the front three-quarter angle with the fro… 1996 Ford Bronco - A black 1990s Ford Bronco full-size SUV parked on gravel with its front bumper removed, exposing a winch and mounting hardware. It sits at… 1996 Ford Bronco - A black Ford Bronco full-size SUV shown from the front three-quarter angle, with chrome grille bearing the Ford oval, amber turn signals, a… 1996 Ford Bronco - Rear view of a black Ford Bronco full-size SUV with a black spare tire cover reading 'FORD BRONCO' and a bucking horse logo, showing chrome… 1996 Ford Bronco - A black two-door Ford Bronco SUV parked on an elevated metal ramp/lift, viewed from the rear passenger side, showing chrome rear bumper, a… 1996 Ford Bronco - Notice the 1/2 inch tube. This is much beefier than the 78-79 Bronco D44's that most of teh members seem to be using. To reference, the tub… 1996 Ford Bronco - Cleaned up axle pics. Keith plasma'ed off the shock mounts, and the leaf perch. We then shared the duty of grinding the axle clean. 1996 Ford Bronco - Aint she purdy! 1996 Ford Bronco - Left is for D44HD-----Right is for 8.8 D44-Yukon--------8.8-Precision Gear 1996 Ford Bronco - Built Axle (Well except calipers and brakes). 1996 Ford Bronco - The axle is super clean inside, and all the parts were cleaned up by myself. Keith welded the u-joint caps to the yokes, and now she is alm… 1996 Ford Bronco - last pic 1996 Ford Bronco - No more TTB! 1996 Ford Bronco - Floating front half of Bko 1996 Ford Bronco - Axle is hung 1996 Ford Bronco - First axle flex test. I was limited due to the rear tire stuffing, and not having enough clearence yet. I still have to trim the fenders a… 1996 Ford Bronco - Here is a close up of the stuffed tire. So I am getting ready to install a 2.5" AAL, and possibly trim in the next few days or so. 1996 Ford Bronco - This is a good front pic. Bumper was given to me by Scott S., He is the man. Again the front pic isnt a full representation of full flex. I… 1996 Ford Bronco - A black two-door Ford Bronco full-size SUV shown from a 3/4 front angle with a lift kit and oversized off-road tires on chrome wheels, its…