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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 - A removed solid rear axle assembly rests on two yellow jack stands, with the differential center section facing up and a green drain pan po… 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 of an open differential housing showing the ring gear and carrier assembly with the differential case, exposed after removing the… 1995 Ford Bronco - D60 toner from spicer, and new magnetic pickup from ford. Part numbers visible. 1995 Ford Bronco - A rear differential/axle housing with a silver diff cover rests on the shop floor, supported by a yellow jack stand. In the foreground sit… 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 - Close-up of a disassembled front brake and hub assembly, showing a rusty caliper mounted over a brake rotor with the hub exposed, along wit… 1995 Ford Bronco - A removed rear axle assembly sits on jack stands in a garage or basement, showing the brake rotor, wheel hub with lug studs, and differenti… 1995 Ford Bronco - A front axle assembly removed from the vehicle and supported on a yellow jack stand, showing the drum/rotor hub, differential housing, and… 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 - Underbody view of a lifted vehicle showing a black-painted solid rear axle with differential housing, white leaf springs or control arm mou… 1995 Ford Bronco - close up of caliper. no more than 1/8" clearance to rim. 1995 Ford Bronco - Close-up of a Goodyear Wrangler mud-terrain tire mounted on a black eight-spoke steel wheel with a chrome lip, fitted to a vehicle raised o… 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 - A freshly painted black front differential/axle housing assembly with mounting brackets and pinion tube, resting on a wooden workbench in a… 1995 Ford Bronco - A freshly rebuilt and painted front solid axle assembly rests on a wooden support in a garage, with a large silver coil spring standing upr… 1995 Ford Bronco - A silver/gray-painted coil spring stands vertically atop a black cast axle housing (differential/steering knuckle assembly), photographed o… 1995 Ford Bronco - Close-up of a gray coil spring mounted over a black suspension/axle assembly, likely part of a coilover or shock setup, photographed indoor… 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 - Underbody view of a vehicle chassis showing the rear differential housing, coil spring, and multiple black steel suspension links or bars r… 1995 Ford Bronco - Close-up of steering and suspension components, showing tie rod ends with hex adjusting sleeves and castellated nut with cotter pin, alongs… 1995 Ford Bronco - Underbody view of a lifted Ford Bronco showing the front solid axle with differential cover, coil springs, radius arms, steering linkage, a… 1995 Ford Bronco - Front-end view of a white Ford Bronco with the grille removed, exposing dual auxiliary coolers/heat exchangers, round auxiliary fog lights,… 1995 Ford Bronco - Underside view of a differential with the cover removed, exposing the ring gear and carrier; a hand holds the metal diff cover at left, wit… 1995 Ford Bronco - Two chrome-lipped steel wheels stand upright on carpet indoors; the left has a black-painted 8-spoke center and the right has a bare/polish… 1995 Ford Bronco - A printed spreadsheet titled 'SAS Costs/parts breakdown' listing parts, quantities, costs and part numbers for a solid axle swap, including… 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 - Scanned instruction sheet detailing ball joint removal and installation steps (13 through 38), referencing special tools like D-150-1, D-15… 1995 Ford Bronco - Close-up of an opened differential housing with the cover removed, exposing the ring gear teeth and pinion inside. The gear-marked cast cas… 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.