94 b4000 axle swap/offroad build

The truck as it sits right now, this is updated as the truck progresses the build is in the page's that follow
94 mazda b4000 reg cab shortbox
4.0l , M5OD, 1354M
pvc snorkel (I am a plumber after all)
straight pipe 2'' exhaust with the last 5 feet being 4'' give's it a deeper tone
31 spline 9'' spring over and
Ballistic spring perch's and shock tab's
chev 63'' rear spring's with a 4" block
front 77 F-150 dana 44 high pinion
homemade rear driveshaft
factory front driveshaft
homemade trans crossmemember t-case protection (of sorts)
rusty's off road "high clerance" long arm's
79 F-150 6" deaver super flex spings
37x14x15 IROK bias with full size missmatched spare
steel wheel's
crossover steering
custom highlift mount flushed into the bedside
custom front & rear bumper's
Delta second hand plastic tool box CAME WITH KEY"S
smittybilt xrc 8000 winch
2 hella offroad light's (front) 2 fog lights(rear)
custom tail/turn/brake lights (sick of breaking factory one's)
cobra cb with weatherband 36'' whip on front bumper
custom on board air (DIY)

since im waiting on somemore parts to arrive i figured i would stat a build up of my Dana 30 swap

i am only handling the minor welding as it will be going to a buddys machine shop for all the solid welding... i am only capable of making two pices of metal stick together not of making two pices into one as he calls it

I am using a dana 30 non-cad out of a 96 XJ , it is a high pinion with the larger u-joints 5-760 i plan on running eb coils since they are the closest to the size i need, 19'' at ride height , these will be 21'' (super flex 5.5'')jeep coils is what i would perfer but the longest one's i can find would be 16'' (rustys8.5-9)






after the front end removed along with all the brackets,arms,beams,and crossmembers(tranny)


The new front axle from the local scrap yard


Rusty's long XJ arm kit (high clerance)


Flex joints


some other work i did while in limbo ..

mini truss and some gussets on the ''weak'' front axle


.BODY ARMOR (ok so it was some rust repair/reinforcing)and i know the welds look like poo its 1/8'' plate and was having a heck of a time welding it to the body
http://hphotos-snc3.fbcdn.net/hs039.snc3/12633_365380155133_715295133_10075088_937910_n.jpg

and my barbaric bead breaker

Sounds similar to what I will be doing. Keep us updated.

So far i have 776$ into the build ... that's including shipping on all ordered parts i suspect i will have another 600$ into this when im done

Glad you went through and did this. Yours is furture alone then mine is you well definatly have yours done before mine. Yours has U-joints, mine has CV-jonts on it. As for the reinforcing that something I sound look into doing, I've seen pictures of ones that weren't. I'm going to use Jeep springs for mine that are 21 inches relax, the give an XJ 6.5 inches of lift.

Great build so far.

when i went to reinforce the upper arm mount it didnt look like it but it was warped/tweaked all out of whack i used 1/8'' by 3/4'' to brace around the bushing and cut some more metal out of a large piece of 1/8'' plate for the lower section

It required a couple of clamps to get everything tight to weld

oh and because of my late night fab of my bead breaker i have two tires mounted on rims and rolled the axle under the truck, it should sit about two inches higher when the axle is supporting the weight

Just relized that you welded to cast metal....you need to heat it up first before welding to help the welds stick better. But it looks like you might be fine. Where did you get the Y-link set-up, how much did that run you? I have to say it looks like it might be an easier thing to do then mounting 4 links, like what I'm planning to do.

So I might be able to get away with using jeep coils too.

I have to say I'm very impressed with this build its turning out great. Like you said I'm going to put a D30 under my truck because I can and you meant it too.

kroussinoffroad said:

and my barbaric bead breaker

Click to expand...

I see it comes with the "Tiny dog attached by head" leverage improver

Looking good so far

if i die before i wake wont someone please feed jake...
im better off eatin a couple of big macs then to use him for any leverage help

still waiting for the link brackets

danger sorry i missed your post asking about the links...

the long arm kit is off rusty's off road, it ran my 518 $ to my door step 460$ is list. it should be really easy to mount(and adjust) , and should flex a heck of a lot better (although i still think flex is overrated for what i wheel)

as far as heating cast allready done, im amazed you can see where i welded to the cast

What do you think about these arms?
http://www.ironman4x4fab.com/Jeep_XJ_Long_Arms/XJ_LAK.html

Trying to find a good set without having to fab them.

I'm sorry I just picked my jaw of the ground.....thats more then I will spend on the arms, I'll use what I've got and make it work. I'm told mine are after market ones from procomp. As for shocks, I wish I knew the size I needed so that I can get them while they are on sale.

I can just see that you welded to the axle, if you do weld to the axle anywhere you have to heat up where your going to weld.

Keep up the good work.

i guess i coulda saved 75$ but im still happy with the rusty's arms, i opted for the high clerance one's which were the same price as there standard long arms.

its hard to say but looking at the pics (not that i have a bias opinion) but the rusty's might be a little more beefey

and all the joints are easily replaceable and carried by most fab companys

although in the rusty's coments about the upper arm's it notes that it uses flex joints on the upper arm's as well. THEY arent there just standard rubber bushing's

"Danger" for what it sounds like you are after (somewhat stock ride height ?) it would be hard to make these work. in order for my pinion and caster angles to be correct
i will be runnin somewhere in the ball park of 19'' tall coils at ride height, and thats with the link brackets against the frame, well about 1/4'' down. i will be useing 1/4'' plate under the brackets to attach my modified trans cross member

I'm not going for height, I'm going for by by POS TTB. As for the tranny crossmember, I dont have to modify mine, I have to take off the croosmember that the TTb control arms attached to but might replace it, guys say they didnt replace it after taking it off and are fine.

Where did you order your control arm brakets from, instead of making my own, I might spend the money on pre-made ones, for safty?

well hold onto your jaw i ordered my hd link brackets from ballistic fab for a whoppin 19.95 a piece something like 59$ to my door, i dont know what the dimension of the factory jeep bushing are but these " link brackets" are made to fit the 2.63'' with 9/16'' hole flex joint , they do have some other sizes of the same bracket. and they have alot of other size brackets