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Old 09-04-2012, 08:29 PM   #1
Stang5lgt
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Default Bronco II SAS Dana 30/8.8....

I thought I would share some pics of SAS I am doing for a customer. The BII already has the 4.0 swap done.

Getting a Trussed high pinion Dana 30 with 4.56 gears, and Explorer 8.8 with disc brakes and 4.56 gears. Here are some pics started this morning. Should be done tomorrow. I geared the 8.8 and cut out the pcs. for the brackets last Fri and Sat morning but didn't get as much done since my wife had other plans.

First things first a little boost to start the morning...


Here is the beauty!!!


Had a buddy(Austin TNT's owner) come by to help today...


Bye bye TTB...


Solid axle set in place...


Another solid axle shot!


7.5 out 8.8 in...
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Old 09-04-2012, 08:34 PM   #2
Stang5lgt
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Things left to do brakes, front track bar, steering, upper link on the front axle, hook up shocks, and sway bar. Then test drive. I am shooting for around lunch tomorrow as long as I have help again shouldn't be a problem. We got a ton done from 8am to 3pm with a stop for nap cause I am getting old.

I geared, trussed, and relocated the perches on the Dana 30 in less then hour and half. Getting pretty fast at this now since this was my 4th RBV Dana 30 SAS.
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Old 09-04-2012, 08:37 PM   #3
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I really need to take a trip out there and bring my truck and axles to you. Nice work!!
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Old 09-04-2012, 08:44 PM   #4
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Nice work as usual, Stang.

Those 12 ton HF jackstands were the best investment I've ever made.
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Old 09-04-2012, 08:55 PM   #5
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i'll watch
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Old 09-04-2012, 09:04 PM   #6
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Been getting a lot people asking how to build the arms since this is such an easy swap I am going to give a parts break down....



Here is link to link ends from Ballistic this truck I used Currie JJ but I had them handy so that is why.
http://www.ballisticfabrication.com/...ngs_c_141.html

Bushing as you can see there is two option a premade end or just bushing and make your own. You just use leaf spring bushing. When AMC designed the front 4 link setup on the XJ they made with leaf spring bushings since the parts were easy to come by.
http://www.ballisticfabrication.com/...ies_c_161.html

Bung ends two choices square or round the .250 wall square is cheaper then the .250 wall DOM by half...
http://www.ballisticfabrication.com/...ers_c_176.html

The steel needed...
5 foot of square or round .250 wall 2 inch tube.
Some 1/4 plate to cut the bracket pcs.
And some 9/16s or 14mm bolts if pull your axle from the JY take all the lower control arm bolts they are 14mm.

I make my arms 29-30" bolt hole to bolt hole. Longer then that is a waste(unless you have 10 inches of suspension lift) but that is your call. Pretty simple I make my frame mounts 7 inches tall to got up the frame and hang down below the from 3.25". I make them 6 inches long and I set the edge 1/4" behind the last rivet of the front body mount. That puts you right in front of the tranny cross member. And saves a ton of work. You will have to trim a little off the body mount on the frame to get the mount a 1/4" off the rivet.
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Old 09-04-2012, 09:13 PM   #7
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Here is a pic of the brackets I built for the Merc I have built them all this way. This are just not drilled yet. But you wanna measure 1.5" up from the bottom and 1.5" back and drill a 9/16s hole. By bracing back at 45 degree angle you do a few things, you make a bigger foot print on the frame, they work as skid plates when come down or back up rocks, and your brace the bracket so it will last you many years. The Merc has 23k miles on it's hand made brackets now.

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Old 09-04-2012, 10:26 PM   #8
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Old 09-05-2012, 11:40 AM   #9
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Awesome work!
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Old 09-05-2012, 11:41 AM   #10
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I'm paying attention too, I've got a D30 in stock already. You make it look pretty simple.
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