SAS Done! - Pirate4x4.Com : 4x4 and Off-Road Forum

99frontierxe · 12-29-2004, 09:39 PM

After 3 days of laying on concrete, grinding, welding, lifting, cursing, and drinking, I present to you.... Mongo!

I am in the process of converting a 2wd truck into a beasty 4wd.

For the axle, I used a Dana 44 passanger drop axle from a Jeep Wagoneer. It has been completely rebuilt, and 4.88 gears are installed. For the time being, and financial restraints, it is still open. Plans will include an ARB locker. New balljoints and u-joints have also been installed. I also installed a pair of Warn Premium locking hubs.

Suspension consists of Rancho 44044 leaf springs, and Rancho RSX 99112 shocks. Steering is from PartsMike Parts... which will be modified. For now, I just used the "stock" waggy steering setup, and I am having some bumpsteer. I plan on using a high steer, or cross over steering, but for now, this will have to do.

My brakes are a little soft. The pedal goes down pretty far before slowing, but when mashed to the floor, the truck does stop. If I pump the pedal, pressure on the pedal is much more noticable.

Since I don't have a red star... sorry, I cannot post pics, but I do have a link of all the buildup and before and after pics for you to check out.

http://www.picturetrail.com/gallery/...9779&members=1

TRed · 12-30-2004, 09:31 AM

Bleed your brakes again. I know you think you did it enough, but you didn't.

datz510 · 12-30-2004, 10:01 AM

We went through at least a half bottle of brake fluid bleeding the brakes.

My pathy does the same thing with the brake pedal. Theres just not enough volume in the master cylinder.

99frontierxe · 12-30-2004, 10:11 AM

Andy's is also the same way....

Packman5280 · 12-30-2004, 12:12 PM

Man, 3 days. That is great. Good job!

99frontierxe · 12-30-2004, 12:29 PM

Thanks for the compliments...

I took Mongo out for a drive this morning, and I am impressed. He is doing awesome.

I also checked all the brake lines, and power steering lines for leaks. There were none

I did notice however, that one of my tie rod adjusters is loose. I must have forgot to tighten that one last night, doh! Going to go do that now...

I am getting more used to the bumpsteer, but I would like to solve that when money is more free flowing

Anywayz, thought I would share.

Andrew10591 · 12-31-2004, 07:53 AM

you might want to shave those u-bolts down before they catch on something. Great looking set-up!

99frontierxe · 12-31-2004, 10:45 AM

did that yesterday morning. I also went and retorqued all the bolts, and nothing shifted. I did however, forget to tighten a tie rod adjuster nut when I left my buddies house, but caught it yesterday.

She is driving good, me like.

Spawn_X · 12-31-2004, 02:47 PM

u said "from a 2wd truck" but i saw no TC fab what so ever

Yakker · 12-31-2004, 03:18 PM

Nice dude, its amazing what planning ahead will do for ya. 3 days for an SAS on a nissan is awesome. So now what are you doing for a TC?

99frontierxe · 12-31-2004, 03:58 PM

I am going to use a forward shift Toyota tcase from Marlin Crawler. It will have the 4.7:1 gears in it. I will also have to use a divorced adapter plate from OTT industries. Then, it will be connected to the tranny with a small driveshaft with a coupla u-joints in it. Custom driveshafts front and rear will get power to the axles. I will also have to fab up some crossmembers. The king cab frontier uses a two-piece driveshaft with a carrier bearing, so I will have to cut that x-member out and fab up a new one.... TONS more work coming. I still have alot of homework to do.

But, I got the SAS done, and that was the first milestone.

Yakker, you are absolutely right about planning ahead. There were still a coupla issues that came up and I had to half-ass.

The biggest slow down was the fact that I ordered my draglink too short from Parts Mike, so I had to cut it in half, and sleeve it. It has been welded all around, and two plug welds were made on each end to ensure that the draglink would not come apart. Then, I had to spend a half a day sourcing bushings and HREW tube to make the shackle mounts that go in the frame. I also had to get the hardware for the shackles. But those were pretty much the only problems I had.

99frontierxe · 12-31-2004, 03:59 PM

Quote:

Originally Posted by Spawn_X

u said "from a 2wd truck" but i saw no TC fab what so ever

I hadn't installed the tcase yet. That is "Phase II." The most important part was getting that SAS done. 4wd will happen around February or so.

FatA$$ Toyota · 12-31-2004, 11:34 PM

Looks good but Holy Chit, are you gonna cut down those u bolts or flip em some how.

Spawn_X · 01-01-2005, 01:40 AM

gotcha. re-read your post and saw you said "in PROCESS of converting" so you're fine with me. Now if you said you converted it and TC wasn't in yet, then i'd chew your ass out.

flip those U bolts..

99frontierxe · 01-01-2005, 08:37 AM

Read my post after Andrew's.... I already shaved the fawkin u-bolts

Spawn_X · 01-01-2005, 12:22 PM

screw shaving them - flip'em, its easy enough.

Yakker · 01-01-2005, 01:22 PM

Ya flip those fawkers man, you'll enjoy it afterwords.

.... Thats the KA24DE engine right?

99frontierxe · 01-01-2005, 02:59 PM

Yeah, its the KA24DE...

I am running 4.88s R&P in the front, and the rear sports 4.90s. For the time being, my gears are pretty much right on with the 32" tires. I would like to run 35s, but if I do that, then I need to go with the 5.14/5.13 gearset.

nissanmudder94 · 01-02-2005, 08:28 AM

i think you'll be fine with 4.88s if you wanna go to 35s. i've been running 38 tsls with ka24e / ott divorced case / 4.37s. just suck it up man!

oh by the way- what's your wheelbase now?

99frontierxe · 01-02-2005, 09:31 AM

I dunno, never bothered to measure it...

You think I can turn 35s with only 4.88s in the diffs?

TRed · 01-02-2005, 09:38 AM

I ran 37's for a long time with 433's. It was ok, just need to adjust your driving style.

99frontierxe · 01-02-2005, 10:28 AM

Does anyone know of a good spring shop in the Phoenix/Tucson area? I need some leaf springs for the rear of my truck now...

99frontierxe · 01-21-2005, 06:45 PM

Just an update...

I discovered that the axle housing does in fact, hit the oil pan. I have a nice dent in it now... must address that. I think I will just notch it, and run a remote oil filter somewheres.

Secondly, I have a power steering leak. Simple to fix, I just need to get off my ass and tighten the hose clamp

Mongo is my daily driver, and the handling seems to get better every day. I am used to the bumpsteer, it is hardly noticeable now... at least for me anyways. The suspension travel is amazing with the solid axle setup. I need to get some poseur shots to share, but right now, I have none.

I took him out to play a little today during my lunch break. I grabbed a friend, and we took off into the desert, spinning donuts in the mud, and blasting thru some deep water puddles. It has been pouring down here since 4pm... almost 4 hours.

I cannot wait to get Mongo 100% done. I am jonsing to go out wheeling.

Just thought I would share

12-29-2004, 09:39 PM	#1 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	SAS Done! After 3 days of laying on concrete, grinding, welding, lifting, cursing, and drinking, I present to you.... Mongo! I am in the process of converting a 2wd truck into a beasty 4wd. For the axle, I used a Dana 44 passanger drop axle from a Jeep Wagoneer. It has been completely rebuilt, and 4.88 gears are installed. For the time being, and financial restraints, it is still open. Plans will include an ARB locker. New balljoints and u-joints have also been installed. I also installed a pair of Warn Premium locking hubs. Suspension consists of Rancho 44044 leaf springs, and Rancho RSX 99112 shocks. Steering is from PartsMike Parts... which will be modified. For now, I just used the "stock" waggy steering setup, and I am having some bumpsteer. I plan on using a high steer, or cross over steering, but for now, this will have to do. My brakes are a little soft. The pedal goes down pretty far before slowing, but when mashed to the floor, the truck does stop. If I pump the pedal, pressure on the pedal is much more noticable. Since I don't have a red star... sorry, I cannot post pics, but I do have a link of all the buildup and before and after pics for you to check out. http://www.picturetrail.com/gallery/...9779&members=1 __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

12-30-2004, 09:31 AM	#2 (permalink)
TRed Registered User Join Date: Jun 2002 Member # 12100 Location: Priskitt AZ Posts: 1,168	Bleed your brakes again. I know you think you did it enough, but you didn't. __________________ Quote: Originally Posted by randii if you're a Pickle, rolling down the trail in a Smurf, dispensing bowls of dicks. FWIW, I don't want to see pictures of that, either! Randii

12-30-2004, 10:11 AM	#4 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	Andy's is also the same way.... __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

12-30-2004, 12:29 PM	#6 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	Thanks for the compliments... I took Mongo out for a drive this morning, and I am impressed. He is doing awesome. I also checked all the brake lines, and power steering lines for leaks. There were none I did notice however, that one of my tie rod adjusters is loose. I must have forgot to tighten that one last night, doh! Going to go do that now... I am getting more used to the bumpsteer, but I would like to solve that when money is more free flowing Anywayz, thought I would share. __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

12-31-2004, 10:45 AM	#8 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	did that yesterday morning. I also went and retorqued all the bolts, and nothing shifted. I did however, forget to tighten a tie rod adjuster nut when I left my buddies house, but caught it yesterday. She is driving good, me like. __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

12-30-2004, 10:01 AM	#3 (permalink)
datz510 Wheeler Join Date: Dec 2002 Member # 15426 Location: az Posts: 293	We went through at least a half bottle of brake fluid bleeding the brakes. My pathy does the same thing with the brake pedal. Theres just not enough volume in the master cylinder.

12-30-2004, 12:12 PM	#5 (permalink)
Packman5280 Registered User Join Date: Feb 2004 Member # 27777 Posts: 125	Man, 3 days. That is great. Good job!

12-31-2004, 07:53 AM	#7 (permalink)
Andrew10591 Registered User Join Date: Mar 2004 Member # 28807 Location: Round Rock, TX Posts: 63	you might want to shave those u-bolts down before they catch on something. Great looking set-up!

12-31-2004, 02:47 PM	#9 (permalink)
Spawn_X Banned Join Date: Jan 2003 Member # 16583 Location: Los Angeles, CA Posts: 3,243	u said "from a 2wd truck" but i saw no TC fab what so ever

12-31-2004, 03:18 PM	#10 (permalink)
Yakker Registered User Join Date: Apr 2003 Member # 19069 Location: Wichita, KS Posts: 97	Nice dude, its amazing what planning ahead will do for ya. 3 days for an SAS on a nissan is awesome. So now what are you doing for a TC?

12-31-2004, 03:58 PM	#11 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	I am going to use a forward shift Toyota tcase from Marlin Crawler. It will have the 4.7:1 gears in it. I will also have to use a divorced adapter plate from OTT industries. Then, it will be connected to the tranny with a small driveshaft with a coupla u-joints in it. Custom driveshafts front and rear will get power to the axles. I will also have to fab up some crossmembers. The king cab frontier uses a two-piece driveshaft with a carrier bearing, so I will have to cut that x-member out and fab up a new one.... TONS more work coming. I still have alot of homework to do. But, I got the SAS done, and that was the first milestone. Yakker, you are absolutely right about planning ahead. There were still a coupla issues that came up and I had to half-ass. The biggest slow down was the fact that I ordered my draglink too short from Parts Mike, so I had to cut it in half, and sleeve it. It has been welded all around, and two plug welds were made on each end to ensure that the draglink would not come apart. Then, I had to spend a half a day sourcing bushings and HREW tube to make the shackle mounts that go in the frame. I also had to get the hardware for the shackles. But those were pretty much the only problems I had. __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

12-31-2004, 11:34 PM	#13 (permalink)
FatA$$ Toyota Registered User Join Date: Dec 2001 Member # 8932 Location: Eva, AL Posts: 1,799	Looks good but Holy Chit, are you gonna cut down those u bolts or flip em some how. __________________ [url]http://www.cardomain.com/id/fatasstoyota[/url] [url]http://www.myspace.com/fatazzrunner[/url] 85 Runner, built O.K. I guess, waiting for 1 tons!!!

01-01-2005, 01:40 AM	#14 (permalink)
Spawn_X Banned Join Date: Jan 2003 Member # 16583 Location: Los Angeles, CA Posts: 3,243	gotcha. re-read your post and saw you said "in PROCESS of converting" so you're fine with me. Now if you said you converted it and TC wasn't in yet, then i'd chew your ass out. flip those U bolts..

01-01-2005, 08:37 AM	#15 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	Read my post after Andrew's.... I already shaved the fawkin u-bolts __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

01-01-2005, 12:22 PM	#16 (permalink)
Spawn_X Banned Join Date: Jan 2003 Member # 16583 Location: Los Angeles, CA Posts: 3,243	screw shaving them - flip'em, its easy enough.

01-01-2005, 01:22 PM	#17 (permalink)
Yakker Registered User Join Date: Apr 2003 Member # 19069 Location: Wichita, KS Posts: 97	Ya flip those fawkers man, you'll enjoy it afterwords. .... Thats the KA24DE engine right?

01-01-2005, 02:59 PM	#18 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	Yeah, its the KA24DE... I am running 4.88s R&P in the front, and the rear sports 4.90s. For the time being, my gears are pretty much right on with the 32" tires. I would like to run 35s, but if I do that, then I need to go with the 5.14/5.13 gearset. __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

01-02-2005, 08:28 AM	#19 (permalink)
nissanmudder94 Registered User Join Date: Oct 2002 Member # 14472 Location: Reisterstown, MD / Shepherdstown WV for school Posts: 204	i think you'll be fine with 4.88s if you wanna go to 35s. i've been running 38 tsls with ka24e / ott divorced case / 4.37s. just suck it up man! oh by the way- what's your wheelbase now? __________________ 94 nissan PU. d60 welded, full hydro, 14b detroit, 42 irok stickies. 06 dodge 2500.

01-02-2005, 09:31 AM	#20 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	I dunno, never bothered to measure it... You think I can turn 35s with only 4.88s in the diffs? __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

01-02-2005, 09:38 AM	#21 (permalink)
TRed Registered User Join Date: Jun 2002 Member # 12100 Location: Priskitt AZ Posts: 1,168	I ran 37's for a long time with 433's. It was ok, just need to adjust your driving style. __________________ Quote: Originally Posted by randii if you're a Pickle, rolling down the trail in a Smurf, dispensing bowls of dicks. FWIW, I don't want to see pictures of that, either! Randii

01-02-2005, 10:28 AM	#22 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	Does anyone know of a good spring shop in the Phoenix/Tucson area? I need some leaf springs for the rear of my truck now... __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

01-21-2005, 06:45 PM	#23 (permalink)
99frontierxe Registered User Join Date: Nov 2004 Member # 39257 Location: Tucson, Az Posts: 38	Just an update... I discovered that the axle housing does in fact, hit the oil pan. I have a nice dent in it now... must address that. I think I will just notch it, and run a remote oil filter somewheres. Secondly, I have a power steering leak. Simple to fix, I just need to get off my ass and tighten the hose clamp Mongo is my daily driver, and the handling seems to get better every day. I am used to the bumpsteer, it is hardly noticeable now... at least for me anyways. The suspension travel is amazing with the solid axle setup. I need to get some poseur shots to share, but right now, I have none. I took him out to play a little today during my lunch break. I grabbed a friend, and we took off into the desert, spinning donuts in the mud, and blasting thru some deep water puddles. It has been pouring down here since 4pm... almost 4 hours. I cannot wait to get Mongo 100% done. I am jonsing to go out wheeling. Just thought I would share __________________ SAS and 4wd conversion finally done... Now lockers, and crawler gears.

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