SAS swap

[lve2wheel]

Ok I'm a newbie on this particular site, but not a newbie to the forum world. So I apoligize if this has been over talked about or deserves to be in a different location. Mods please feel free to move if necessary.

Ok I know there has been quite a few discussion topics ( on this forum) regarding the SAS swap on 1st Gen expy's. Mine is a 97 4x4 5.4 xlt. Currently stock but in the process of a body lift, 3" torsion keys and crank up, and 3" spring spacer. running 37's

Im looking at doing a SAS swap in the spring to run 39's or 44's. There is actually a company that makes one. Im curious to know if any one has used this kit, or knows anything about the company. Info is fairly limited on the kit. And I have not yet contacted the company. Word of mouth to me is always more valuable. The price seems kind of cheap @ $750, but only includes the bracketry and hardware.

F-150 Straight axle swap conversion lift kit 4×4 dana 44, 60 1997-2003 | RPM Off Road Fabrication | Metal Fab Work

Or is it just smarter to fab up my own SAS swap or have a offroad shop do it.

Any posstive inquiries will be more than helpful.

Thanks in advance.

 

[Bowesmobile]

Thats interesting. I didn't know they had this swap out there. The price seems right since it comes minus the springs. The material looks good and the design seems solid. Looks like a good starter kit for the money.

 

[BIG GREEN FORD]

I am looking into this also. Need to know if I can still stay with my rear 3.73 gear ratio or did I have to swap it out also. And can I stay with the same transfercase

 

[Bowesmobile]

Big green,

You can keep the gear ratio. You just need a D44 or D60 with the same ratio. Transfer case doesn't need to change either. You will have to get a new front driveshaft that is the correct length. But if you're going that high you're probably going to have to lengthen the rear as well.

 

[BIG GREEN FORD]

Okay makes since now cuz I hate to let my ratio go its got me out of some missed up places

 

[toms89]

Samrider777 has done a solid axle swap. But his ride is custom built by himself. I don't recall seeing any others that have done a sas in this forum but there may be.

http://www.expeditionforum.com/f52/expedition-2000-sas-1-ton-19712/index12.html

 

[tonydiv]

This kit is really only a small part of the entire project. As stated above, you are certainly going to need the front axle, drive shafts, the rear lift to match, gears (I certainly wouldn't want to turn anything larger than a 37" tire with 3.73 gears) and then all of the "may as well's".

 

[BIG GREEN FORD]

So with 37" I can still use my 3.73????

 

[Madmaxwell87]

Or is it just smarter to fab up my own SAS swap or have a offroad shop do it.

It says on the sight you will have to do some fab work for the spring hanger, you'll also have to take off all the old ifs and ifs brackets as well as fab up steering, brake lines, drive shafts, springs, and get an axle(a somewhat rare and popular axle with off roaders making it expensive. You might have better luck having the shop modify it for a Superduty Dana 50 or 60 as they're much more popular and available making them cheaper)

With all of that, unless you or a buddy have fabrication experience, you will probably have to take the truck to an off road shop anyways to get all of that done. This kit would take away fabrication time and cost but could the shop do the same things for you for cheaper than the $790 this kit costs? Talk to a shop and ask them what they would charge for making a crossmember and shackles as that's the main part of the kit. You're probably gonna be looking at around $2-3k to get a solid axle up front if you buy everything new and include fabrication/installation labor.

 

[Madmaxwell87]

So with 37" I can still use my 3.73????

I wouldn't. The truck would be extremely slow on the street and need 4Lo for most normal 4Hi driving. Generally its 4.10s for 33s, 4.56 for 35s, and 4.88 for 37's. That's to get the truck driving and shifting somewhat close to stock.

The diesel guys can get away with 35-37s and 3.73s cause they have the torque and heavy duty axles, transmissions and springs to handle it. The torque on those components created by trying to move those big heavy tires with less mechanical advantage could eat up 1/2 components.

Do people do it? Absolutely but usually at the cost of trannys or axle shafts and long term reliability.

 

[BIG GREEN FORD]

I wouldn't. The truck would be extremely slow on the street and need 4Lo for most normal 4Hi driving. Generally its 4.10s for 33s, 4.56 for 35s, and 4.88 for 37's. That's to get the truck driving and shifting somewhat close to stock.

The diesel guys can get away with 35-37s and 3.73s cause they have the torque and heavy duty axles, transmissions and springs to handle it. The torque on those components created by trying to move those big heavy tires with less mechanical advantage could eat up 1/2 components.

Do people do it? Absolutely but usually at the cost of trannys or axle shafts and long term reliability.

Sounds like I'm staying with my 315 then lol

 

[lve2wheel]

Thanks for all the insight guys. Im not really worried about changing the gears, Figured thats already a must if i go bigger than 37's. At that point it will strictly be a mud/offroad truck. I'm well aware of the fab work that will need to be done. Not a huge concern other than steering linkages. ( still working out the details on that.)

I havent talked to my fab guys yet, so I'm not sure if its cheaper to just have them fab everything, or if it's cheaper to go with this kit. ( looking to do it in the spring after winter so no rush, and its not a DD so it can sit and be worked on)

I beleive the Expys came with an 8.8 out back if im not mistaken. Is that strong enough to hold up to 39's-44's? or should i start thinking about a rear axle too?

And I've heard of some guys running front super duty springs on the back to obtain lift. Any truth to this? and what are the ratio's? Like a stock sping gives X amount of lift. 2" lift sping gives you X amount of lift and so forth...

Once again THANK YOU all for your input.

 

[tonydiv]

A 5.4 4x4 will have the Ford 9.75" rear end which should be fine for them big meats.

 

[lve2wheel]

Tonydiv... I've been looking at getting that same front bumper for mine. Did you get it from BluelakeOffraod, or Tactical Armor Group? both companies look to be selling the same exact bumper. How was the customer service, happy with the product? Fit and finish etc? I was thinking about ordering it with out the hoop though. Did you go with shackles or D-rings? and which lighting option did you go with? (use their lights or put your own in?)

 

[BIG GREEN FORD]

Tonydiv... I've been looking at getting that same front bumper for mine. Did you get it from BluelakeOffraod, or Tactical Armor Group? both companies look to be selling the same exact bumper. How was the customer service, happy with the product? Fit and finish etc? I was thinking about ordering it with out the hoop though. Did you go with shackles or D-rings? and which lighting option did you go with? (use their lights or put your own in?)

Tactical armor group he has it on his signature and he has the shackle one (just in case he forgets to answer)

 

[lve2wheel]

Tactical armor group he has it on his signature and he has the shackle one (just in case he forgets to answer)

Thanks I guess I should of read it.

 

[BIG GREEN FORD]

Thanks I guess I should of read it.

Lol maybe

 

[tonydiv]

What he said.

 

[southernexpy38s]

Hi guys it's been a while, but I also did a solid axle swap, I'm running a dana 44 up front, 8.8 rear, both chromoly shafts, 4.88 gears, and lockers, on 40" tsl tires. I ain't had a problem out of it yet. On or off road.

 

[Canadian Expy]

Hi guys it's been a while, but I also did a solid axle swap, I'm running a dana 44 up front, 8.8 rear, both chromoly shafts, 4.88 gears, and lockers, on 40" tsl tires. I ain't had a problem out of it yet. On or off road. View attachment 9261View attachment 9262

You should do a write and post some pics on how and what you used to do the swap, I'd be interested in the steering end of things??