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SAS-D44/D60FF swap

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

61 photos
1995 Ford Bronco - Ford rear axle assembly, likely from a Bronco or similar truck, undergoing maintenance or modification.Ford rear axle assembly, likely from a Bronco or similar truck, undergoing maintenance or modification. AI caption 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.3/8" custom caliper mounting plate by Jim H. 3/4T chevy disc brake setup. Plan to use exact same up front. Owner 1995 Ford Bronco - Close-up view of the internal components of a vehicle's differential assembly.Close-up view of the internal components of a vehicle's differential assembly. AI caption 1995 Ford Bronco - D60 toner from spicer, and new magnetic pickup from ford. Part numbers visible.D60 toner from spicer, and new magnetic pickup from ford. Part numbers visible. Owner 1995 Ford Bronco - Rear axle differential assembly with new Motorcraft parts laid out for installation.Rear axle differential assembly with new Motorcraft parts laid out for installation. AI caption 1995 Ford Bronco - will be drilling a 13/16" hole up top to mount the VSS sensor.will be drilling a 13/16" hole up top to mount the VSS sensor. Owner 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.I did grind the diff for clearance. Ground my current 8.8 as well. Best I can measure there is 1/8" difference. Owner 1995 Ford Bronco - This is a close-up view of a vehicle's brake system, focusing on the caliper and rotor assembly.This is a close-up view of a vehicle's brake system, focusing on the caliper and rotor assembly. AI caption 1995 Ford Bronco - A disassembled rear axle assembly, likely for a Ford Bronco, is supported by yellow jack stands in a garage.A disassembled rear axle assembly, likely for a Ford Bronco, is supported by yellow jack stands in a garage. AI caption 1995 Ford Bronco - Rear axle assembly with brake caliper and brake lines, supported by a jack stand, likely undergoing modification or repair.Rear axle assembly with brake caliper and brake lines, supported by a jack stand, likely undergoing modification or repair. AI caption 1995 Ford Bronco - Cut off old low hanging shock mount and fabbed these up out of 2x2 x .25" square tube.Cut off old low hanging shock mount and fabbed these up out of 2x2 x .25" square tube. Owner 1995 Ford Bronco - Detroit locker. I pulled this so we could press the toner ring on.Detroit locker. I pulled this so we could press the toner ring on. Owner 1995 Ford Bronco - shot of toner, with VSS sensor mounted up top. got the air gap between to apx. 1mm.shot of toner, with VSS sensor mounted up top. got the air gap between to apx. 1mm. Owner 1995 Ford Bronco - another shot of sensor mountinganother shot of sensor mounting Owner 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…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… Owner 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").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"). Owner 1995 Ford Bronco - overall shot. Shows clearance of shock mounts.overall shot. Shows clearance of shock mounts. Owner 1995 Ford Bronco - VSS sensor mounted on top of diff.VSS sensor mounted on top of diff. Owner 1995 Ford Bronco - Now using Ujoint "ubolt" type connector (1330 series) instead of flange.Now using Ujoint "ubolt" type connector (1330 series) instead of flange. Owner 1995 Ford Bronco - Close-up view of the rear axle, driveshaft, and suspension components of a vehicle.Close-up view of the rear axle, driveshaft, and suspension components of a vehicle. AI caption 1995 Ford Bronco - close up of caliper. no more than 1/8" clearance to rim.close up of caliper. no more than 1/8" clearance to rim. Owner 1995 Ford Bronco - Close-up of a Goodyear Wrangler off-road tire and black wheel.Close-up of a Goodyear Wrangler off-road tire and black wheel. AI caption 1995 Ford Bronco - Right now, until front is converted, it's 8 lug rear, and 5 lug front.Right now, until front is converted, it's 8 lug rear, and 5 lug front. Owner 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…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… Owner 1995 Ford Bronco - Chevy Flat Tops. Going to use PartsMike.com stuff for high steer.Chevy Flat Tops. Going to use PartsMike.com stuff for high steer. Owner 1995 Ford Bronco - E4OD Crossmember mod needed on pass side for Cage Radius ArmsE4OD Crossmember mod needed on pass side for Cage Radius Arms Owner 1995 Ford Bronco - D44 cleaned up, ready for paint. this is my garage "staging" area.D44 cleaned up, ready for paint. this is my garage "staging" area. Owner 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,…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,… Owner 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…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… Owner 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…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… Owner 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…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… Owner 1995 Ford Bronco - Front axle assembly, likely for a 4x4 vehicle, is black and appears to be recently serviced or painted.Front axle assembly, likely for a 4x4 vehicle, is black and appears to be recently serviced or painted. AI caption 1995 Ford Bronco - Vehicle axle and suspension parts are disassembled and arranged on the floor, likely for repair or modification.Vehicle axle and suspension parts are disassembled and arranged on the floor, likely for repair or modification. AI caption 1995 Ford Bronco - A close-up view of a suspension coil and shock assembly, likely undergoing maintenance or modification.A close-up view of a suspension coil and shock assembly, likely undergoing maintenance or modification. AI caption 1995 Ford Bronco - A gray coil spring is mounted on a black axle assembly, likely for an off-road vehicle modification.A gray coil spring is mounted on a black axle assembly, likely for an off-road vehicle modification. AI caption 1995 Ford Bronco - Axle all ready to be put underAxle all ready to be put under Owner 1995 Ford Bronco - TTB was taken out, upper coil mounts off, ready to begin putting new '78 solid D44 under truck.TTB was taken out, upper coil mounts off, ready to begin putting new '78 solid D44 under truck. Owner 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"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" Owner 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.This was the final design of the E4OD crossmember. Had to do this since the cage arms and mounting bracket are so long. Owner 1995 Ford Bronco - locating axle under trucklocating axle under truck Owner 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.shot before coil was in, and caliper not mounted yet. I had already pre-ground the caliper and mounting bracket to clearance 15" wheels. Owner 1995 Ford Bronco - caliper mounted. used a superlift stainless line meant for 8-12" lifted cheb. K20 truck, measures 31"caliper mounted. used a superlift stainless line meant for 8-12" lifted cheb. K20 truck, measures 31" Owner 1995 Ford Bronco - cage radius arm and mounting bracket now sit about 3/4" inch in front of the e4OD xmembercage radius arm and mounting bracket now sit about 3/4" inch in front of the e4OD xmember Owner 1995 Ford Bronco - with weight on the coils, I had from what others had experieced, the same superflex bow problem.with weight on the coils, I had from what others had experieced, the same superflex bow problem. Owner 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.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. Owner 1995 Ford Bronco - all done, except for some tuning on all the work.all done, except for some tuning on all the work. Owner 1995 Ford Bronco - go to subsection after SAS flex misc. pics for better shots.go to subsection after SAS flex misc. pics for better shots. Owner 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…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… Owner 1995 Ford Bronco - Detailed view of a vehicle's modified suspension and axle system.Detailed view of a vehicle's modified suspension and axle system. AI caption 1995 Ford Bronco - Detail shot of suspension parts, including a large coil spring and adjustable linkages.Detail shot of suspension parts, including a large coil spring and adjustable linkages. AI caption 1995 Ford Bronco - Custom suspension and axle work on a vehicle, focusing on off-road modifications.Custom suspension and axle work on a vehicle, focusing on off-road modifications. AI caption 1995 Ford Bronco - Front view of a 1995 Ford Bronco with added transmission coolers and a winch.Front view of a 1995 Ford Bronco with added transmission coolers and a winch. AI caption 1995 Ford Bronco - Differential housing and suspension components are visible in this close-up shot.Differential housing and suspension components are visible in this close-up shot. AI caption 1995 Ford Bronco - Two aftermarket wheels are displayed, one with a black center and the other with a polished finish.Two aftermarket wheels are displayed, one with a black center and the other with a polished finish. AI caption 1995 Ford Bronco - This document details the costs and parts breakdown for a SAS-D44/D60FF swap.This document details the costs and parts breakdown for a SAS-D44/D60FF swap. AI caption 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.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. Owner 1995 Ford Bronco - D44 8 lug outer...inner larger bearing race.D44 8 lug outer...inner larger bearing race. Owner 1995 Ford Bronco - This document contains detailed information, possibly related to vehicle specifications or performance data.This document contains detailed information, possibly related to vehicle specifications or performance data. AI caption 1995 Ford Bronco - Close-up view of differential gears and housing, showing a stamped part number.Close-up view of differential gears and housing, showing a stamped part number. AI caption 1995 Ford Bronco - D60 rear with detroit and toner ring addedD60 rear with detroit and toner ring added Owner 1995 Ford Bronco - 78-79 D44 front with the unusual "chip", but it's there for a purpose.78-79 D44 front with the unusual "chip", but it's there for a purpose. Owner