Mark Zoelch > 1995 Ford Bronco > open folder SAS-D44/D60FF swap

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3/8" custom caliper mounting plate by Jim H. 3/4T chevy disc brake setup. Plan to use exact same up...
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D60 toner from spicer, and new magnetic pickup from ford. Part numbers visible.
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will be drilling a 13/16" hole up top to mount the VSS sensor.
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I did grind the diff for clearance. Ground my current 8.8 as well. Best I can measure there is 1/8...
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Cut off old low hanging shock mount and fabbed these up out of 2x2 x .25" square tube.
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Detroit locker. I pulled this so we could press the toner ring on.
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shot of toner, with VSS sensor mounted up top. got the air gap between to apx. 1mm.
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another shot of sensor mounting
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D60 about ready, you can also see I welded on some new 1/4" flat plate to the spring perches after s...
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Fabbed upper ubolt plate, 3/8" with 1/4" risers and offset 1" center hole for the ORD zero rate leaf...
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overall shot. Shows clearance of shock mounts.
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VSS sensor mounted on top of diff.
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Now using Ujoint "ubolt" type connector (1330 series) instead of flange.
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close up of caliper. no more than 1/8" clearance to rim.
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Right now, until front is converted, it's 8 lug rear, and 5 lug front.
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Speaking of front, here are many of the components that can be had "used". D44 78-79 housing, every...
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Chevy Flat Tops. Going to use PartsMike.com stuff for high steer.
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E4OD Crossmember mod needed on pass side for Cage Radius Arms
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D44 cleaned up, ready for paint. this is my garage "staging" area.
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As part of the front SAS, I will be cutting the xmember, so the power steering tube needs to go, in ...
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Hard to tell here, but the 8 lug 3/4T chevy hub and rotor is beefier, as evidenced by it weighing in...
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again a bit tough to tell, but the big bearing chevy 44 spindle on the left uses a bigger inner bear...
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Drivers inner D44 TTB top and the 3.25" longer '78 bottom. This is evidence the diff sits this more ...
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Axle all ready to be put under
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TTB was taken out, upper coil mounts off, ready to begin putting new '78 solid D44 under truck.
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My old Rancho 4" coil used thicker coil rod, but was only 19" in length (compressed to 15.5"). Supe...
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This was the final design of the E4OD crossmember. Had to do this since the cage arms and mounting ...
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locating axle under truck
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shot before coil was in, and caliper not mounted yet. I had already pre-ground the caliper and moun...
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caliper mounted. used a superlift stainless line meant for 8-12" lifted cheb. K20 truck, measures 3...
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cage radius arm and mounting bracket now sit about 3/4" inch in front of the e4OD xmember
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with weight on the coils, I had from what others had experieced, the same superflex bow problem.
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this is after the fix, wedge in bottom welded to the cup, made a new upper attaching strap, and adde...
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all done, except for some tuning on all the work.
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go to subsection after SAS flex misc. pics for better shots.
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Track bar. Originally tried using the stock 78-79 bar. I redid that and now am running 1.125 DOM (...
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I don't have the hi steer arms on at this time, clearance issues. This pic just for reference on h...
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D44 8 lug outer...inner larger bearing race.
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D60 rear with detroit and toner ring added
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78-79 D44 front with the unusual "chip", but it's there for a purpose.
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