Onthetrailto - 1993 2.3t SAS project

[Onthetrailto]

Got it all in last night! Had to finish up this morning.

https://flic.kr/p/2qPu7WC

https://flic.kr/p/2qPpC7x

Troubleshooting rough engagement into gear and some whining noise coming from the transmission. Sounds similar to a power steering pump. I can't remember if that is normal. The floorpan is no longer sealed and packed with sound deadener, so it could just be that.

I used parts store ATF that was rated for mercon (recommended by the Hanes manual). Any thoughts?

 

[Onthetrailto]

Made some progress lately. I made a shifter bezel and adapted a jeep shifter boot for the t-case.

https://flic.kr/p/2rpdJ5T

https://flic.kr/p/2rpjcSy

Last night I was able to get the factory suspension out and slide the axle underneath for the first time! I'm using a long arm kit from Barnes4wd. Now I need to get some measurements so I can order springs and shocks. I'm hoping to keep the lift very mild ~4 inches.

https://flic.kr/p/2rpi1Yy

https://flic.kr/p/2rpi1Yt

 

[bobbywalter]

jbg 2 in coils probably be close. or Cherokee 2 overs

 

[bobbywalter]

set it on the stock coils to see what it does

 

[Onthetrailto]

jbg 2 in coils probably be close. or Cherokee 2 overs

Am I looking for Early Bronco coils?

I have some stock Grand Cherokee Coils. Once I trim up the engine cross member for a bit more clearance, my plan is to check how much they compress and go from there. They have a pretty soft spring rate compared to the ranger.

 

[bobbywalter]

Am I looking for Early Bronco coils?

I have some stock Grand Cherokee Coils. Once I trim up the engine cross member for a bit more clearance, my plan is to check how much they compress and go from there. They have a pretty soft spring rate compared to the ranger.

that would be good make a block seat to dial in ride height and gtg

 

[Onthetrailto]

Last night I got the measurements for the upper control arms. I should have those mounted this week. Did some math and figured the 3 inch JBG coils are going to be just right for my desired ride height. Ordered them this morning.

I'm also waiting on a crossover steering kit and track bar mount from Barnes 4wd.

I can see the finish line!

 

[Shran]

Sweet. I love old school builds like this!

 

[Onthetrailto]

Sweet. I love old school builds like this!

Thank you! I've had this truck for 13 years and I finally have the resources to make it what I want.

https://flic.kr/p/2rtXJDQ

It's been sitting on blocks for a month.. too long

 

[Shran]

My Explorer SAS project has been sitting on jack stands for well over a year now... I totally understand.

 

[Onthetrailto]

https://flic.kr/p/2rz9kQC

Got it on the road today! Wound up going with the 3.5 inch early bronco coil and bilstein 5100s. I also brought up the rear to be nearly level.

It still needs a few things like an alignment and I need to bench bleed the brake master cylinder, but otherwise I am extremely happy with it.

 

[Onthetrailto]

Shortly after finishing up, I noticed some serious vibration above 40 mph. I have traced it to the front driveshaft, which I removed for the time being. After removal, the vibrations reduced considerably. The Bronco II driveshaft slip yoke connects at the transfer case. I noticed that there is a pretty severe angle on the u-joint there that could be contributing to the vibration:

https://flic.kr/p/2rMaBUX

I am also not super happy with how little of the slip yoke is actually making contact in the t-case snout. The Dana 30 does not have locking hubs, nor axle disconnect, so the front driveshaft is always engaged and spinning when moving.

I'm thinking that there are a few options, some of which can be applied together:

1. Adjust the pinion angle down on the front axle

2. Get the front driveshaft extended or replaced

3. Add a double-cardan joint to the slip yoke end

4. Add a slip yoke to the center of the driveshaft

5. Replace the bushings on the transmission crossmember and transmission mount

6. Replace the rear driveshaft u-joints

What are your thoughts? I have driven several hundred miles without the front driveshaft and it is better, but it kind of defeats the purpose of a SAS.