My Dana 30 SAS

[982WDRanger]

Finally got it...!

So it has been bugging me that my Dana 30 pinion preload was way out of wack, like 45in. lbs., but said the hell with it and buttoned up the axle anyways. So finally today, I got irritated enough to go out in the garage and tear it all apart again and see WTF happened.

Come to find out it was just simply the bearing! Using the set-up bearing to measure the preload was what threw it all off when I used the new one with shims I added with the set-up one, threw the final measurement out of place. So to all future Dana axle builders, don't use a set up bearing to determine the preload!!! Now it is just right 13-14 in. lbs.

Well that was all I needed to do until I put it in. And guess what, the madness starts monday, build day 1, will be posting lots of pics, stay updated with the progress.

 

[escort_gts]

I thought you used the setup bearings on the carrier.

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[982WDRanger]

I did, as well as on the pinion. But everything was okay with the carrier.

 

[escort_gts]

I've never used setup bearings on the pinion.

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[nooch450]

I've never used setup bearings on the pinion.

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You either need a pinion inner bearing race that is ground down if the shims are under that or a inner pinion bearing with the inside ground out if the shims are under that. If not you chance destroying your new bearing or bearing race (depending on where shims are) every time you press/tap the bearing or race off...

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[escort_gts]

Let me rephrase that...I never set pinion preload with setup bearings. Sorry for the confusion.

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[982WDRanger]

It has begun!

Today was Day 1 of my SAS, finally! I call it an SAS but its really a 2wd --> 4wd conversion. But I am swapping out my "front axle" for a solid one...but w/e. Go a good start on the rear. Don't have time to post up pics now but will be soon, I took plenty to explain just what I am doing as I go.

Hoping to have my pinion angle all set tomm, and be rolling again. Any input on a good way to set my pinion angle?

 

[88_Eddie]

hook up everything, put a jack under the pinion on the diff, set it up so everything looks good, tack your perches in, take everything out and burn it in for good.

probably somewhere around 6-9 degrees for a ranger. my b2 is right around 12 or so, but it's a shorter wheelbase.

 

[escort_gts]

You want the same angles at the transfercase and pinion. For example, the two are parallel to each other; 5 degrees at both ends. This is for a single ujoint shaft.

A double cardan ujoint, you want the pinion to be at 0.

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[982WDRanger]

Build Day 1

So as a said I started my swap lastnight and everything went great, minus betting a few splatter burns!(damn welding). Thanks for the input on pinion angle too guys hoping to get that set tonight. Here is what I have done so far.

Here is my truck as it stands before the swap.

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Pulled it in the garage and began to tear down!

First went the bed.

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Since I was replacing everything we just unbolted the hangers and dropped out the old 7.5.

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Tried to keep my old hanger because they were just replaced but the hanger bolts were stuck in the leafs and said f*ck it, my buddy had a set kicking around, so we painted them and bolted them right up.

Bye Bye 7.5!

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Out with the old and in with the new

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Threw in the new 6inch leafs from Skyjacker and some drop shackles from Autozone, yeah I'm a cheap ass, w/e.

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...that is as far as we got, called it a night at 9ish. I had to work this morning so didn't wanna stay up too late. Hoping to get the new axle in tonight. Be back with updates soon.

 

[86MUDRCJ]

Liking the build man. You turn out some pretty decent fab.

 

[982WDRanger]

Thanks, not much fab in the rear other than burning in the leaf perches and shock tabs, hopefully get those in tomm. The front on the other hand...gunna be a lot of wire to be burnt. Can't wait actually, like to hack stuff up and weld it all back together.

Should be done the rear by Monday, and turn it around and start on the front Tuesday, I start my vacation from work then...!

 

[982WDRanger]

Build Day 2, Pinion Angle

So had a good start the other night and got all the old junk out and got some new stuff in. Got the new axle in and bolted her up loosely to figure out the pinion angle I need.

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Ended up with 8 degrees in the end I believe, if I get a vibration in my drive line I can just shim it later but it seems to be ok. Slapped the axle up in there, measure stock angle with an angle finder, figure t-case angle and determined new 8.8 angle based on those angles.

We jacked up the front and leveled out the truck to get a more accurate angle, and to see what my ride height was going to be.

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Measure it all out, 47inches to the top of the wheel well. What I started with was 39 and some change. So she is lifted!!

Once we figured out the angle we jacked up the nose of the axle and I tacked in the new spring perches. While we were in the decided to slap on new shock mounts too.

Weld Porn: Kids look away

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Shock Tabs from Ruff Stuff:

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After got that all burned in, called it a night and would paint it all up tomorrow.

 

[982WDRanger]

Paint

Cleaned up the frame, and went to town today, not much to say, picture are worth a thousand words.

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I used Chassis Saver, it a little bit expensive but is the best stuff I have ever used. The finish is smooth as glass and hard as a rock. Buy mine on ebay, get 5qts for the price of 4.

Be back tomm, button it all up with brakes and tires, put the bed back on and turn it around and prep for the dana 30 to go in.

 

[Str8sixfan]

Lookin' good, lookin' good!