"MAX" Solid Axle Swap Project Thread(MANY HUGE PICS)

[Rinkrat456]

Well, I finally got some time to sit down and upload pics of what I've been working on. Oh, BTW, my truck's name is Max, so there goes the explanation for the title.


[B]Here's the project. 1996 2WD GMC Sonoma extended cab getting a solid front axle suspension. [/B]

My purpose for building this: This isn't a build for flex nor articulation like most SASers, this is a way to make a 2wd pickup 4x4, and honestly nothing more. I found the first thing I had to come to terms with, was exactly what I want out of this build. I'm a sportsman through and through, hunting and fishing all season long. My truck is a daily driver (not during the build, but for years after) and I use it to get to work every day and school which is a 5 hour trip mostly highway. I hunt whenever I'm not working on the truck, working, or at school. Corn fields, bean fields, soy fields, back woods, swamps, streams and hill climbs in the fall. When winter rolls around and lakes freeze, I'm ice fishing (I live in MN) and climbing steep banks (damn near verticle) to get from the ice onto the nearest road. 5 days a week it's my daily driver, weekends it's my offroad beast which must be reliable in all aspects...I've overbuilt everything. Once a year (now that I'll be lifted I joined a trail riding club) I'll go to a weekend trail ride 4 hours away. So basically, I needed a man's truck, and some how I've gotten through all of the above with a 2wd for years.

So, onto the bill of materials:
[B][U]FRONT[/U] [/B]
Front 1987 Jeep Grand Wagoneer Dana 44, 6x5.5" bolt pattern
Passenger flat top knuckle milled drilled and tapped for crossover steering
Sky-Manufacturing "thick" billet steering arm, Sky stud kit for passenger knuckle 4" drop pitman arm from Jeep Cherokee
Draglink from pitman arm to passenger knuckle provided by Sky-Manufacturing
Tie rod in lower location on knuckles
Chevy dual steering stabilizers for front mounted to tie rod
Bilstein 5150 shocks all 4 corners: 255/70 valving front, about 12" travel (they're all leaking before I even put them on, probably going with Bilstein 7100's)
Sky Toyota full width crossmember
Sky shackle mounts
Sky axle flip kits
Custom length, fully boxed shackles
3" Tuff Country EZ-Ride lift springs for 73-87 Full size Chevy, spring rate 325lb
Yukon Power-Lok limited slip differential for front
4.30 Dana ring and pinion
1/2 ton single piston calipers
12" cross drilled and slotted rotors
23" stainless kevlar wrapped brake lines
Rock Crusher Dana 44 differential cover

[B][U]REAR[/U] [/B]
Axle over leaf in rear
Custom leaf spring pack, 2wd main leaf with #2 #3 and overload leafs from ZR2
1.5" lift shackles (lift shackles + ZR2 pack already lifted it 4")
1995 Rear Isuzu Rodeo Dana 44, 6x5.5" bolt pattern
Yukon Power-lok Limited slip differential for rear
4.30 Dana gears
Vented 12-1/4" rotors
1/2 ton single piston calipers
Bilstein 5150 12" travel shocks, 170/60 valving rear (again, leaking, probably going with 7100's in same travel and valving)
23" stainless brake line
Rock Crusher Dana 44 differential cover

Then 2" body lift all around.

I'm expecting no less than 9" of suspension lift front and rear, plus the 2" body lift.


What I started as, little 2wd, aint he cute?!

[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/P7230005.jpg[/IMG]
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/P7230006.jpg[/IMG]


Stage 2 was a body lift and 30's front, 31's rear on black Cragar rims.
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/100_5898.jpg[/IMG]

Stage 3 was the hybrid leaf pack and longer shackles, still 30's front 31's rear.a
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/DSC00791.jpg[/IMG]

And this is what stage 4 should look like.
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/Newdesign.jpg[/IMG]

[Rinkrat456]

So, onto the parts:

Front leaf spring pack, rear eye shackle mount from Sky Manufacturing
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00835.jpg[/IMG]

"Thick" billet high steer arm from Sky
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00837.jpg[/IMG]

Stud kit, from Sky
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00836.jpg[/IMG]


Toyota Full Width Sky Crossmember
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00847.jpg[/IMG]

[Rinkrat456]

Front calilper mounts have been cleaned up and powder coated.
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00829.jpg[/IMG]

3" Tuff-Country EZ-Ride springs
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00819.jpg[/IMG]

4 12" Bilstein 5150 shocks, probably not keeping these for very long, might not even put them on. They're known for leaks, and getting the first package with 1 already leaking proved that. The replacement shock I got leaked, so after that I checked all the shocks during compression and yep, all are leaking. Probably going with Bilstein 7100's in 12" travel, same valving.
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00874.jpg[/IMG]

170/60 Valving for the rear shocks
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00810.jpg[/IMG]

255/70 for the front
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00809.jpg[/IMG]

[Rinkrat456]

4" drop pitman arm to reduce drag link angles and prevent bumpsteer
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00818.jpg[/IMG]

Yukon Power-Lok limited slip differentials front and rear
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00806.jpg[/IMG]

12" Cross drilled and slotted front disc rotors
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00798.jpg[/IMG]

12-1/4" Vented rear disc rotors
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00772.jpg[/IMG]

1/2 Ton calipers front and rear
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00783.jpg[/IMG]

[Rinkrat456]

Flat top knuckles milled drilled and tapped for Hi-steer, but I'm only using the drag link holes, running the tie rod in the stock location to make using dual stabilizers easier.
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00636.jpg[/IMG]

Painted John Deere green, kinda going with a green/black combo for the suspension
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00645.jpg[/IMG]

[Rinkrat456]

Front Dana 44
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00618.jpg[/IMG]

Rear Dana 44 (old pic not cleaned up, I'll get a better one)
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00753.jpg[/IMG]

As Max pulled into the garage
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00858.jpg[/IMG]

Getting ripped apart
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00870.jpg[/IMG]

[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00873.jpg[/IMG]

As I'm done with school now, I'll be able to work on this more and continue. Overall, should be done by Wednesday at the latest.

[Rinkrat456]

Forgot to mention tires.

Five 325/70R17 Nitto Terra Grappler A/T (35x13.25R17)
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/0424071519a.jpg[/IMG]

Here's the winter rims to combat MN salty roads, basically shitters.
Black Cragar soft 8's, 17x9, 6x5.5" bolt pattern 5" of backspacing
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/DSC00661.jpg[/IMG]

And the new rims on order through work. (I work for Discount Tire Co., and these needed to be ordered straight from American Racing because they're Teflon Coated)
17x9 American Racing Chamber rims, same specs as above. These are my summer/nice weather rims.
[IMG]http://static.summitracing.com/global/images/prod/large/are-3985_w.jpg[/IMG]

[Rinkrat456]

I just got off the phone with the place I ordered my shocks from, and I'm sending all 4 5150's back free of charge, and when those arrive they will ship out 4 7100's in the same valving. Cost another $260, but oh well.

[GeorgesBlazah]

I thought you said no pics till its done! :finger:

[NC4x4]

I would say "Nice!" and act surprised....
but I think I've seen all these pictures somewhere before. :D

[shiftit]

i have those cragars on my truck, thanks for callin them shitters

jk at $50 each i cant complain

[Flamed 98]

[QUOTE=shiftit;4122516]i have those cragars on my truck, thanks for callin them shitters
[/QUOTE]
Same here :p


I can already tell this is going to be a good project thread. :cool: I can't wait to see more pictures. Did you drill and tap the flat tops yourself, or did you have someone do it? Where did you get the high steer arm?

[monkeymouse]

Damn, I am excited to say the least.

[LostHighway]

Rinkrat, congrats on the build! This thing is gonna look awesome. You'll be able to take it out in the field no worries. Plus I can't imagine MN winters with rwd.

[Rinkrat456]

[quote=Flamed 98;4122632]Same here :p


I can already tell this is going to be a good project thread. :cool: I can't wait to see more pictures. Did you drill and tap the flat tops yourself, or did you have someone do it? Where did you get the high steer arm?[/quote]
Steering arm is from Sky-Manufacturing. I needed the "thick" arm to clear over the top of my leaf spring pack. The flat top knuckles I sent out to have milled, drilled and tapped.

[Rinkrat456]

[quote=shiftit;4122516]i have those cragars on my truck, thanks for callin them shitters

jk at $50 each i cant complain[/quote]At $50 bucks a pop, I can afford to run them on Minnesota salty roads and not worry about replacing them. The AR rims on the other hand, even through work are expensive.

That's why I ordered 5 Cragar rims...1 for the spare since it's cheaper than buying 1 AR rim for the spare.

[Rinkrat456]

First snag. I'm having a bitch of a time getting the pitman arm off. No matter how much torque I throw at the nut, it wont turn...either direction. I'm not sure if it's reverse thread or standard, but I tried both ways and no luck.

Any ideas? I don't need it to come off until tomorrow, but I've got some time today so I might as well.
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00880.jpg[/IMG]

[lilbushhead]

breakerbar and long ass pipe!

[89-S-Dime]

Find someone with a compressor and an impact wrench/gun and once you get nut off you might have to use a puller to get the pitman off...........that is what i had to do.

good luck

[NC4x4]

The longest breaker bar you can find. The longer it is, the easier it will be to turn.
Also, soak it in Liquid Wrench of PB Blaster every half hour or so.

[monkeymouse]

I gave in and used a nut splitter on mine.

[Mcfly Minis]

wrench, with a long pipe over it, you will proly need a pitman arm puller also.

[insane3639]

damn its about fricken time good god jk jk but seriously i was waiting forever for a build for a lifted truck to come to this site that can at least stay active

anyways for the nut use a breaker bar and lots of wd-40 type of penetrator what some do is use that the night befor and then i would do it again in the morning and let it sit all day then try and yes try both ways cause it could be a reverse cut thread

[greencactus3]

damn. sumone's been saving up lol

[Rinkrat456]

Got the pitman arm off. It was reverse thread. Ended up having to use a 6' extension on the adjustable wrench. Damn near torqued the entire truck off the jackstands. Rear is done, minus shocks. Damn the D44 rear is wide! lol Looks great though.

Waiting for my uncles to come over tonight and weld up my x-member.

Gotta get back out into the garage.
I'll have more pics tonight.

[Nazgulmagefreak]

Dude, you are my idol. Be sure to post prices when your done. And lots of pics of the new front end.

I hope I can do this in the next 2 years.

TerranceP.

[orangesonoma]

sweet..good luck!

[AmosM823]

Should look good when it's done! You have fun with that, be sure to post pics of the process.

[s10W]

nice, can't wait to see this finished. Should be a awesome truck

[Rinkrat456]

If you insist.

We didn't get much done at all today as I had hoped. I ran into a major snag with the front axle build up and not being able to press the ball joints into the knuckles all the way. I even rented the ball joint press from Autozone but it didn't have the pressure neccessary to put them in. So, I dropped them off at a shop to pick up tomorrow morning.

Also today I realized that my puny 18" jackstands weren't tall enough so I spent a good majority of today traveling the Twin Cities looking for stores with jacks tall enough. Ended up finding some nice 12 ton 30" jackstands and even those are on the second to last notch. Cinder (sp) blocks just weren't cutting it. They started to crumble as the truck was being cut into and at one point the driver side stack of cinder (sp) blocks crumbled completely leaving the truck at a dangerous angle.

Did mock up the front crossmember and leaf springs, along with roughly where the front axle is going. Right now it's about 1" too far forward. From the center line of the original wheels, the axle should be about 1-1.5" forward with leaf springs. Didn't get to cut anything today or weld, spent most of today trying to safely put my truck back on all four jackstands.

I also rebuilt the rear axle today with new bearings, Yukon Power-Lok limited slip and replaced the disc brakes.

[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00890.jpg[/IMG]
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00894.jpg[/IMG]
[IMG]http://i113.photobucket.com/albums/n214/Rinkrat456/SAS/DSC00892.jpg[/IMG]

[Zygoat]

sounds like you got a fair bit done to me. those kind of setbacks are a givin on any big project.

[shiftit]

easier way to get that bolt off would have been to heat it up and give it a few whacks with a hammer.

[Nolly_Nolly]

man thats sweet. Your truck is definatly going to look sick once this is done. Keep up the good work!