Solid Axle Swap

[Expeditionary]

I have found out today that my front end is blown out (front axle) so I am going to be needing to do a swap with a junk axle in the front.

Here's the dilemma... should I do a solid axle swap up front since I already have to do major repairs on the front end?
What would be the major tasks of this?
What Axles will work with my transfercase?
What would I be getting into in doing this???

 

[Canadian Expy]

I've only seen this done once but I'm sure there may be more out there. I think they used a Dana 44 off a F150 or Bronco from 78-79. Used leaf springs up front but you could do coils. Alot of work and fab to do this(coils more than leafs) but unless you plan on running huge tires or massive power I'd stick with the front you got. My 2 cents ...it would be cool !

 

[rburch]

It depends on what kind of setup you are going to run, leaf springs or 4 link. Both are going to have equal amount of fab work.

4 link is going to give you the best suspension articulation, travel, and ride quality. But it will end up costing about 500-1000 more because of all the steel and parts you are going to have to buy.

 

[Expeditionary]

im going to leaf it in the front. The point of doing this will be to fix the current problem i have of a 6000lb yard ornament of an expedition and save myself the time later on to be able to run MASSIVE tires (40"+++) also I could do a nice 4" suspension lift for the front and the rear to give a badass look to the truck while it sits on 35s (which it will for a while)

I just have no clue how much this is going to cost me
Would the D44 work with my Tcase?
And can I get it out of a truck that has already been leafed upfront. Or will i need to make the mounts too?

 

[SourMashII]

All Ford axles are Driver Side out.. I would look at running S-Duty axles.

Cheap (Rock Krawlers hate unit bearing axles) and if you shop right, can find the whole suspension. 2005 up S-Duty was Coil sprung in the front and used basciallya 4 link suspension.

I would also consider a TTB swap into the front. Ferd's TTB is an amazing set up,, and it will give you some go fast options the SFA won't be as conducive to.

THere is a bloke that did a TTB 44 swap under his Avalanche, just for a Baja type application. Street driven Pre Runner, but impressive air.

 

[Canadian Expy]

Here's a guy that did it, maybe I should do this instead of the fabtech
http://www.fourwheeler.com/featuredvehicles/25378_1998_ford_expedition/index.html

 

[Expeditionary]

Here's a guy that did it, maybe I should do this instead of the fabtech
http://www.fourwheeler.com/featuredvehicles/25378_1998_ford_expedition/index.html

thats all good but i dont have money out the ass right now...

Also. I have no clue what a TTB is but I am seriously considering this.
Could I just take the whole front out of like a f250 or excursion with leafsprings, and just weld the leaf mounts to my frame and call it a day?

My friend was telling me about it and he seems to think that with the right parts, know how, and tools, that it can be done in a nearly sleepless weekend.
Is he just BSing or is there some truth to this?


As always money is THE ONLY object

 

[Canadian Expy]

Not that easy ... You've got steering you got to figure out!? It's usally the hardest part. Plus new driveshafts. and making sure geometry is all right.
I think its a lot harder than a weekend unless your friend has done it before!
My friend took weeks to get his front end right in a truck he built, and he works as a engineer. (it did work out real well when done)

 

[tonydiv]

One of the biggest issues is gettting everything lined up and square. If you're off by a quarter of an inch on one of those measurements, the truck becomes a death trap.

It also won't be a quick job. As it progresses, you'll find numerous compataiblity issues will arise. Some will be minor, but others may take some real engineering to solve. That's just the nature of a 'swap' project.

There's probably a reason why, even though there are millions of F150s and expeditions out there, no one makes a 4 link solid axle swap kit for it. That's most likely, the reason that most people have decided to put leaf springs up front.


If money is the most important thing, just go get a boneyard front diff and pop it in. It is the cheapest and easiest way to get the truck back on the road.

 

[SourMashII]

TTB = umm.. Bronco front suspension for the easy button. Twin Torsion Beam is the clinical term.

It is what was used to replace ALL solid front axles from 1980 - 1985.5, and then it was the half and 3/4 ton front end through the end of the OBS body style. (1996 for Bronc and F150, 97 for .75 and 1t)

Once they became a "SuperDuty" (snicker snicker....) they got a Solid Front axle in .75 and 1 ton ratings, and our IFS replaced TTB in the half ton pickups and station wagons.
Technically, our platform was offered as a .75 ton, but a weak .75 ton in comparison to a true F250, pre 98 or post 98.



(I snicker at the current gen of .75 and 1t wearing the SuperDuty badging, because prior to their introduction, it was reserved for F450 and above...)

 

[99 Expy]

In your shoes, I would just swap in a used axle from a salvage yard. It will be much cheaper and quicker in the end. Even though I really want to swap in a ZF6, if my tranny goes before I get the time and money, I'll end up putting another auto in. It sucks, but better than not having a vehicle.

Try http://www.car-part.com/ Seems to be a pretty good site for parts.

 

[humboldtexpy]

look for a company call fabritech there used to be a link on jeffs bronco graveyard the kit was for an f150 but it should definatley work on the front

 

[cody.agler]

I have seen it done to an Expy out in Vegas. The guy put a Dana 44 as stated before under it. I personally have looked into do this you would have to buy the Dana 44 axle and have matching gears most likely 3.55 or at least that is what mine had. Then you have to buy an actual conversion kit. I found conversion kits ranging in price from $800-$1700. No as it goes for the actual work I have no idea because I have not gotten that far in my own personal research yet.

 

[SkyJumper]

With the wt of this vehicle, and the size tires you are looking to run a D44 will not last long. A HD/HP D44 out of a early F250 will work, but best choice would be a D60 out of a F250-F350. That will get you to at least 3/4 ton setup up front and then a sterling out back to round out the driveline. There is no kit for this as most will have to be fabbed up in the garage or have someone make it. There is fab shops online that you can get some of the parts needed, like steering arm, and trac bar. Those are simple and easlily attainable as you will want to make them out of DOM tubing. Then the matter of radius arms(extended type), RA rear mount brackets, coil buckets(upper and lower), shock hoops or shock upper buckets. Trac bar upper and lower brackets, driveshafts, transfer, manual shifter for xfer, fab to mount in cab and lingage to connect the two. That is just the front, then the rear will need leafs, front and rear leaf hangers, shock upper and lower brackets, driveshaft.

If you are going leaf up front then you will still need a trac bar, and mounts, front fabbed crossmember and front hangers and then rear hangers. shock provisions.

The nicer setup would be coil spring front instead of the leaf setup. Fab work will have to be done on both setups, just not as much with the leaf setup.

You need to budget yourself around 5-6k for start to finish. I have done plenty of SAS setups in the past with my Bronco's, so beleive me when I say that it is not cheap no matter how you go about it. You may save on some parts and the bulk of it is in the front and rear ends. Not to mention gears, shafts, and lockers, and axle rebuild kits.

If you have the mind frame that it would be a cheap conversion compared to fixing the existing issues with your front, you are sadly mistaken and will only be disappointed when you start it and can not finish because it is costly, more than you anticipated.

Find everything you need, price them, source them, and then create a price sheet, then budget accordingly.

 

[panda24619]

speaking of TTB! my buddy is taking his 2wd prerunner expy and doing TTB and putting in a 351. thing should be BAD ASS! i keep trying to get him to sign up here, but he has yet to. haha o well.