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My 94 Sport SAS


P93suafilo

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After a year of collecting parts, I think I am finally ready to start a build thread. Nothing really different than what’s been done in the past except that it’s mine and I am not reading about someone else’s. Any advice is welcome as this is my first SAS build. The plan is to be done by Easter 2022, help me keep to it lol!
94 Explorer Sport (white) 4.0– No name yet…Any Ideas?
Here is the list of parts I have and need to get. Doing it this way so I can add up the cost in the end.
Front Axle: 1977 F-150 Dana 44 (gonna try to slide it as far forward as I can)
-5.13 Yukon gears w/ a Detroit Auto Locker
-JD Radius Arms
-JD Coil Seats
-JD Radius Arm Bushings
-XJ 4.5" Coil springs
-EB Coil Towers (They are about 1" taller than stock)
-F250 Shock Tower
-Stock Axle Shafts
-New Consumables (Ball Joints, Bearings, U-Joints)
-Stock Pitman Arm
-Fabricated Heim Steering (not built yet)
-Fabricated Heim Trackbar
-Barnes Upper Tracbar bracket
Rear Axle: 1978 F-150 Ford 9”
-5.13 Yukon gears w/ a Full Spool (wanted a locker but this was cheaper at the moment)
-Barnes SOA Anti-Wrap perches w/ U-bolts and shock mounts
-Barnes Pinion Guard
-Stock Springs
-Stock Drums
Tires: 35/12.50/15 General Grabbers – wanted 37s but got too good of a deal on this set.
Still Need List:
-Shocks (not 100% decided here)
-Driveshaft U-joints
-Driveshafts (modify stock till I can get some tom woods)
Eventually List:
Sliders
Winch
Doubler (I have the 1350 already just need to get me a Steelman special)

Pics to come and I will keep this post updated.
 
Last edited:


BlackBII

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Awesome. Can't wait to see this one get done!
 

dvdswan

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Keep your mind like an umbrella, it only works if its open... Continually learning.
Sounds great, can't wait to see.

Axle track bar I would fab because you want it to be the same angle as the drag link to help reduce bump steer IIRC.
 

P93suafilo

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Sounds great, can't wait to see.

Axle track bar I would fab because you want it to be the same angle as the drag link to help reduce bump steer IIRC.
That’s the plan. I have the heim ends just not the tube or the lower bracket yet. I wanted to see where things were lining up first before I bought or built one.
 

P93suafilo

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Okay so little victories right will get the project done. Tonight I pressed the ball joint out and painted the knuckles. Then I replaced the cracked thrust washers in my Detroit and put the ring on it. Hopefully the next couple days I’ll get the 44 set up. The 9” I set up over Christmas break, I wish all diffs were as easy as the 9”.
 

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P93suafilo

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4WD
Weekend update- I got everything ready to start the 44 regear to 5.13s and while setting up the pinion realized the install kit I had from Richmond Gear was missing the pinion bearing shims. So that put a hold on things, I called around and found a local shop "The Jeep Guys" and they told me to come snag a handful because they had a draw full of leftover shims. Grabbed those Saturday so my goal for this week is to get the 44 regeared and the wedges moved in. Then just a JY run and I should be done with the 44.
 

dvdswan

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My credo
Keep your mind like an umbrella, it only works if its open... Continually learning.
Nice. When I did my D44 I was lucky enough to find a used ARB with 5.13s on it for cheap. It's always easier to set up gears/axles with the axle out.
 

P93suafilo

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Made some progress tonight! I got the 44 all set up. I even hung my whiteboard up.

Now I gotta slide the wedges in... hopefully @BlackBII has some time this week to supervise my welding. Part of this project is I want to learn to mig weld so that I can fabricate bumpers/sliders/whatever I want.
 

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BlackBII

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I'll do what I can to get you laying perfect mig beads :icon_thumby:
 

dvdswan

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Keep your mind like an umbrella, it only works if its open... Continually learning.
Buy some small pieces of different sized metal and practice practice practice. Make sure you weld in different positions too. Upside down is the best.
 

ryan

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are the axles 5 lug or 8 lug? Feel like I've seen a lot of great deals for 8x6.5 sets lately, might be hard to find with something less than a 40" tire though
 

P93suafilo

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2WD / 4WD
4WD
are the axles 5 lug or 8 lug? Feel like I've seen a lot of great deals for 8x6.5 sets lately, might be hard to find with something less than a 40" tire though
They are 5x5.5. I have seen a ton of deals on those 8lug wheels and it would be fun to 40s
 

P93suafilo

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Lehi UT
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1997, 89, 94
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Ford
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4.0 V6
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4.0
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Manual
2WD / 4WD
4WD
Made a good bit of progress tonight. Took some measurements, cut the wedges off, and tacked up the driver side.

After talking with Kirby N. I decided to slide the wedges in 2 1/4” and added 2* of caster. Shout out to @BlackBII for helping me walk through the numbers.

Got to get the passenger side cleaned up and tacked into place and then burn them in with some help lol.
 

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BlackBII

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Tire Size
33
Happy I could help! We'll get those axles setup and underneath your Explorer in no time 👍
 

ryan

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They are 5x5.5. I have seen a ton of deals on those 8lug wheels and it would be fun to 40s
Should be able to run JK takeoffs then though, should get a screaming deal on people who are going from 37s to 40s/tons.
 

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