138Modified Forums
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 Posted:2/10/2008 09:29 |
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The most difficult part of the solid axle swap for me was the coil placement. The full size coil buckets were the key up top rather than trying to modify the stock Bronco 2 ones, mounting these adjusted the ride height easily. But the lower spring perches were at a terrible angle, leaning open towards the front end with that much lift. Even though I had the lowest drop brackets for the radius arms I could get without totally making new ones, they caused the coils to bow outwards under the vehicle weight. So I had to cut the perches 3/4 around, taking note as to where the coil first touches them as the lowest point, and shaping it in a sort of coil and welding sides to it. It fixed it after a few tries but in the end it lifted the front end 2.5 more inches so I had to move the coil buckets up accordingly.
The radius arm brackets mount securely to the frame by drilling new holes, but in my application one of the driver side transmision mount holes was 1/8" forwards of where the bracket needed to be to put the tires at the stock wheelbase. So I went with that and pulled my measurement off of the rear axle tube-to-bracket and transferring that # to the passenger side. The radius arms didn't want to mate to the much narrower frame so after the driver side was fairly secure with at least 2 bolts in place, I used a ratchet strap to pull them together, and a jack under the passenger side to put it right where I wanted it for drilling and finally bolting it on.
The trac bar used to center the vehicle is also a bit tricky because it mounts right under the steering box and theres really no room for a bracket. I used 6"x4" angle and braced it with a steel rod to the frame under the motors oil pan. It was only approx 10 " away from the bracket and theres no other way to get that much stability elsewhere. the trac bar is under extreme pressure, almost contantly while off-road, so skimping here is not an option, the bracket would eventually bend and weaken till it fails. And your vehicle will dangerously unload itself to the ground.
On a lighter note, the 9" rear end was a dream, I just cut the spring perches and shock mounts off the axle tube and used the ones fron the old Bronco 2 rear axle. I raised the pinion angle for a better u-joint position, was only 3 degrees difference for my truck, and welded them back on careful not to get the axle tube to hot. After its mounted to the leaf springs I then welded on the shock brackets to the axle housing.It was easy compared to the front.
With all that installed I began the brakelines and fittings. I thought it would be a nightmare but i was lucky enough to find a knowlegable Oreilly's guy with a brakeline book and we hashed it out. On the proportioning valve under the driver floor pan I used the driver side outlet hardline because it was the shorter one,and plugged the passenger one and removed it. Then I mounted a Bronco 2 rear rubber line with 2 outlets to that hardline up front to the pumpkin, its plenty long for the front. I bought the stock hardlines mated to short rubber lines for the Dana 44, and all new calipers, that was pretty much it. The rear 9" lines fit the Bronco 2 line and splitter already, so i bolted it up.
Here are a few sites i refered to for encouragement.
http://ford.off-road.com/ford/article/articleDetail.jsp?id=198396
http://www.broncoii4x4.com/dana44/dana_44_solid_axle_swap.php
http://www.therangerstation.com/tech_library/Dana44_leafspring_conversion.htm
Cap |
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Posted:2/11/2008 00:00 |
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i think threw trial and error youve done a killer job. ive pretty much watched you turn that truck into a real beast. i cant wait to see it locked. |
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Posted:3/9/2008 10:41 |
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I've taken it to the local off-road area called snowball seven times now, 2 times were all day long. So far it has done very well. The first few trips out I was very careful but the last few times I've been pushing it more and more. It's so much more capable now, the wide wheel base and 33 inch tires totally hook up on any kind of gravel or dirt. Even trees if im not paying attention, haha.
Cap |
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