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-   -   A/Os 1/2 ton axle rebuild and SASsy thread -with a pic or two (https://www.ford-trucks.com/forums/1165375-a-os-1-2-ton-axle-rebuild-and-sassy-thread-with-a-pic-or-two.html)

alpha/omega 05-29-2012 08:10 PM

A/Os 1/2 ton axle rebuild and SASsy thread -with a pic or two
 
Since FTE could use another SAS thread heres what Ive been working on the past couple weeks for a friend.


84 F150
http://i253.photobucket.com/albums/h...3-48-09_18.jpg

9" rebuild

housing stripped bare and wire wheeled
http://i253.photobucket.com/albums/h...-59-25_229.jpg

Had to weld one spring pad back on
http://i253.photobucket.com/albums/h...-59-54_359.jpg

Painted gloss black
http://i253.photobucket.com/albums/h...-45-38_879.jpg

The 3rd member already had 4.10 gears so we kept that but gutted the open carrier for a mini spool. The rest of the parts in this pic are 44 stuff
http://i253.photobucket.com/albums/h...-49-52_260.jpg

everything removed and cleaned up
http://i253.photobucket.com/albums/h...-09-04_499.jpg

Open carrier with the ring gear removed. Bust it in half
http://i253.photobucket.com/albums/h...-42-05_311.jpg

Knock out the 3 roll pins and remove the cross pin, spiders and side gears
http://i253.photobucket.com/albums/h...-42-26_158.jpg

Throw 'em in a box
http://i253.photobucket.com/albums/h...-34-33_232.jpg

Its cute :D
http://i253.photobucket.com/albums/h...-45-37_255.jpg

Stick it in the deep half of the carrier along with the shims that were behind the side gears
http://i253.photobucket.com/albums/h...-42-51_187.jpg

http://i253.photobucket.com/albums/h...-43-12_168.jpg

http://i253.photobucket.com/albums/h...-43-20_565.jpg

Stock cross pin on the left chromoly on the right.
http://i253.photobucket.com/albums/h...-40-57_364.jpg

Stick it in the hole and drive one of the roll pins back in. :-X19
http://i253.photobucket.com/albums/h...0-42-38_74.jpg

Slap it back together and bolt your ring gear up - torqued to 60ft lbs with red locktight
http://i253.photobucket.com/albums/h...-57-49_608.jpg

alpha/omega 05-29-2012 08:24 PM

Set it back in the 3rd member - caps torqued to 60ft lbs with red locktight
http://i253.photobucket.com/albums/h...-47-16_190.jpg

use the spanner wrench you made because youre too cheap to buy one
http://i253.photobucket.com/albums/h...-02-53_114.jpg

http://i253.photobucket.com/albums/h...-19-08_678.jpg

Had to put a new pinion seal in
http://i253.photobucket.com/albums/h...-04-48_344.jpg

Cast coat aluminum high heat paint....
http://i253.photobucket.com/albums/h...-03-43_318.jpg

Put it in
http://i253.photobucket.com/albums/h...-25-46_936.jpg

Press new studs in as necessary
http://i253.photobucket.com/albums/h...-58-18_981.jpg

Paint the brake backing plates
http://i253.photobucket.com/albums/h...-49-43_392.jpg

Slap 'em in and install new brakes. No parking brake
http://i253.photobucket.com/albums/h...-22-20_769.jpg

http://i253.photobucket.com/albums/h...-13-56_968.jpg

Bend lines
http://i253.photobucket.com/albums/h...-00-31_354.jpg

Slap it in the truck. I reused the factory 2" block but I think he is going to buy a set of 4" springs. The front is a little high and I want to ditch the block.
http://i253.photobucket.com/albums/h...-27-51_186.jpg

Hes also bought a new set of shocks but they havent come in yet.

alpha/omega 05-29-2012 08:43 PM

Greasy rusty turd as delivered
http://i253.photobucket.com/albums/h...-45-46_567.jpg

Stripped down and wire wheeled
http://i253.photobucket.com/albums/h...-59-22_611.jpg

Paint
http://i253.photobucket.com/albums/h...4-43-57_98.jpg

The axle came with 3.25 gears. Ive never seen one with that high of a gear and I dont think its factory. Not sure why. Oh well, order gears, carrier and install kit.
http://i253.photobucket.com/albums/h...7-59-39_30.jpg

Remove the side gears and spiders from your 3.91-down carrier and install them into your 3.92-up carrier. Basically the same as the 9" carrier above except dont try to bust this one in half :D Notice the difference in offset.
http://i253.photobucket.com/albums/h...-33-57_664.jpg

Everthing together before the first go'round on the shims. The ring gear bolts were torqued to 55ft lbs with red locktight.
http://i253.photobucket.com/albums/h...-37-14_705.jpg

Press the pinion bearing in
http://i253.photobucket.com/albums/h...-19-58_654.jpg


Ready to go
http://i253.photobucket.com/albums/h...9-21-43_78.jpg

Race
http://i253.photobucket.com/albums/h...-31-34_518.jpg

Pinion
http://i253.photobucket.com/albums/h...9-32-39_13.jpg

http://i253.photobucket.com/albums/h...-01-19_186.jpg

Zang! Took 4 tries for me to get right. :-banghead
http://i253.photobucket.com/albums/h...1-40-35_43.jpg

alpha/omega 05-29-2012 08:53 PM

Hubs and rotors
http://i253.photobucket.com/albums/h...-51-08_444.jpg

Press new races in, pack bearings and install the outer wheel seal.
http://i253.photobucket.com/albums/h...-10-43_556.jpg

Slap the shafts in
http://i253.photobucket.com/albums/h...4-07-40_22.jpg

Add finishing touch to piss off owner
http://i253.photobucket.com/albums/h...-14-15_551.jpg

Caliper bracket, spindle, wheel hub/rotor and outer wheel bearings on.
http://i253.photobucket.com/albums/h...-12-07_645.jpg

Install blingness and repeat.
http://i253.photobucket.com/albums/h...-08-21_321.jpg

Wait on parts from the big brown chariot. 4" Deaver Superflex springs and 7* bushing set
http://i253.photobucket.com/albums/h...-23-03_664.jpg

Install brake lines, 7" extended brake line for a 79 F150 and radius arms. Basically complete in this pic minus calipers.
http://i253.photobucket.com/albums/h...-11-51_212.jpg

alpha/omega 05-29-2012 09:06 PM

Now the fun stuff...

For tie rods, drag link and trac bar we are using 1.5 x .250 DOM with 5 -3/4 thread x 3/4 bore and 1- 3/4 thread x 5/8 bore chromemoly heims with kevlar liners. All hardware is grade 8 and pinned with a cotter key so it cant wiggle loose. We are also using misalignment spacers at the top of the passenger knuckle and at the pitman arm. You will need to drill the taper out of the knuckles and the pitman arm to make this all work.

http://i253.photobucket.com/albums/h...-42-19_599.jpg

More on this later.


Get that POS out of there
http://i253.photobucket.com/albums/h...-36-16_911.jpg

I salute you! Link'd
http://i253.photobucket.com/albums/h...-59-55_705.jpg

All gone
http://i253.photobucket.com/albums/h...-00-52_420.jpg

Roll the new axle under there
http://i253.photobucket.com/albums/h...-37-33_871.jpg

Bolt your blingdaddy superflex springs into the stock 84 coil buckets - I did this out of spite to the interwebs since Ive read numerous times it will not work and that 73-79 buckets are required.
http://i253.photobucket.com/albums/h...-38-50_438.jpg

bottoms
http://i253.photobucket.com/albums/h...-38-55_816.jpg

I used stock 79 F150 radius arm brackets instead of the TTBs. If you notch the brackets to clear the body mount and use the rear ttb bracket hole on the frame in the front hole of the radius arm bracket it works perfectly.

notch them like this...
http://i253.photobucket.com/albums/h...-06-19_727.jpg

bolt that shat up!
http://i253.photobucket.com/albums/h...-46-14_727.jpg

hav24wheel 05-29-2012 09:16 PM

Mini spool bad. Better off making one with spiders n two cross pins.


Everything else looks good.

alpha/omega 05-29-2012 09:26 PM

http://i253.photobucket.com/albums/h...-46-41_243.jpg

http://i253.photobucket.com/albums/h...-27-57_475.jpg

Trac bar bracket cut down from an old set of 4 link brackets
http://i253.photobucket.com/albums/h...-06-49_777.jpg

http://i253.photobucket.com/albums/h...-17-12_970.jpg

http://i253.photobucket.com/albums/h...-33-32_655.jpg

All done
http://i253.photobucket.com/albums/h...-51-44_596.jpg

Trac bar and drag link are within 1/2* of being perfect.
http://i253.photobucket.com/albums/h...-59-38_472.jpg

http://i253.photobucket.com/albums/h...-59-08_307.jpg

yes, thats a chrome diff cover.


On the brakes...
A 84 (not sure what other years for complete certain but Im pretty sure 80-96) the brake lines come off both sides of the frame with a seperate line coming from the proportioning valve. For this truck I used the 79 style lines and routed the line from the pumpkin (where it meets the juction block and is distributed to each caliper) straight up to the proportioning valve in the driver side line hole and capped off the passenger side with a pipe plug.



Next for this project will be a MSD 6al and coil, electric fuel pump and regulator, new valve springs to match the cam, shocks and a few other little things. I may also end up swapping torque converters for something a little higher stall.

alpha/omega 05-29-2012 09:27 PM

Dave, I agree but I guess it will work until it doesnt.

im2tall33 05-30-2012 03:05 PM

thats a nice looking 84!!!

77mud 05-30-2012 03:17 PM

Neg reps for putting on the chrome cover instead of the pink one

alpha/omega 05-30-2012 04:21 PM

Paying customers get whatever color/finish diff cover they want.

77mud 05-30-2012 04:24 PM

lol i hear that... you talked him into a 460 yet?

alpha/omega 05-30-2012 04:44 PM

Naaa...

Im going to tinker on this engine until we pretty much max it out.

77mud 05-30-2012 05:15 PM

you say it was 302 or 351?

ibleedblue1385 05-30-2012 05:55 PM

Thats a stout looking truck.
Good work!

alpha/omega 05-30-2012 06:13 PM

its a 302 with E303 hyd roller, 1.6 roller rockers, Edelbrick performer and a 600cfm Edelbrick carb. Nothing really fancy but should be fairly reliable.



ibleedblue...your name is Jesse right? Regardless, thanks.

kjett 05-30-2012 08:54 PM

Looks good. I guess the brake line and coil bucket info we talked about worked out for ya. Oh, and nice looking steering links and track bar ya got there ;)

Looks good. Now that is done, get to work on George! Next race at Mountainview is June 30, you got a place to crash here with the wife and kiddo!

alpha/omega 05-30-2012 09:00 PM

I used 79 buckets and ttb style brakes on my last SAS. Always thought this way was better and was pretty sure its what you did based on the alcoholic haze I call a memory.


Ive got to finish this truck, a 78 and a 79 before I can finish George. The way it seems I'll never race my own junk again. I would say I'm the new Cheeto but at least my build plans have remained the same albeit unfinished

77mud 05-31-2012 06:46 PM

plus your making a profit and not just asking a profit then selling for pennies on the dolla!

alpha/omega 07-11-2012 12:48 PM

more pics

Paul took the bench seat out and we set the bucket seat and harness in there. I will be building brackets about 5-6" tall for them to mount to.

http://i253.photobucket.com/albums/h...-56-44_824.jpg

Bolted up some "3.5 inch" add a leafs from JBG. I didnt do a before measurement but Id say it only lifted the truck 2" like all other add a leaf kits

Dear Paul, take a picture for me



Front receiver hitch behind the front bumper.

http://i253.photobucket.com/albums/h...-22-59_836.jpg

A class 4 receiver was cut and sleeved with 3 x 3 x .250 square tube with 8" of overlap and then bolted to the frame with some 2 x 3 x .375 angle.

http://i253.photobucket.com/albums/h...-01-15_960.jpg

http://i253.photobucket.com/albums/h...-22-46_134.jpg

http://i253.photobucket.com/albums/h...6-53-07_57.jpg

http://i253.photobucket.com/albums/h...22-18-47_8.jpg

Im going to build a little bracket at the end of a piece of 2x2 square tube to hold the license plate. Basically you would never know it was there until you took the plate off.

captain p4 07-11-2012 02:07 PM

Bumper's crooked :flip

joe f350 07-11-2012 03:14 PM


Originally Posted by captain p4 (Post 12047291)
Bumper's crooked :flip

u must have hung it on there

captain p4 07-11-2012 04:36 PM

I'm not goin to tell you what ******* did to make it crooked.

77mud 07-11-2012 05:07 PM

i seen Joe on a you tube vid he posted on FB...... he talkes exactly like he types.... very slow/stuttered and you couldn't understand a word of it

alpha/omega 07-12-2012 11:39 AM

Pics

Add a leafs
http://i253.photobucket.com/albums/h...-03-23_591.jpg

Passenger side done. We came back later and put the little clamps on.
http://i253.photobucket.com/albums/h...-53-36_489.jpg

Holley blue pump and regulator. 3/8" line from the tank to carb run on the passenger side frame rail.
http://i253.photobucket.com/albums/h...-02-56_671.jpg

http://i253.photobucket.com/albums/h...-56-01_735.jpg

Seats
http://i253.photobucket.com/albums/h...-17-43_976.jpg

MSD 6AL digital
http://i253.photobucket.com/albums/h...-08-09_754.jpg

I forgot to post this pic on the first page. The 73-79 radius arm bracket was cut and bolted to either side of the front body mount. The front most hole of the 73-79 bracket lines up perfectly with the rear most hole of the ttb radius arm bracket.

http://i253.photobucket.com/albums/h...6-13_235-1.jpg

hav24wheel 07-12-2012 09:13 PM

Hey, get one o them semi license plate holders n put it on the bumper. Than flip the plate up, n put the insert in. Just a idea.


Also, regulator mounted to the body?

alpha/omega 07-12-2012 09:24 PM

Thats a good idea Dave.


Yes the regulator is mounted to the firewall. I didnt want to put it on the inner fenders because they are plastic and 28 years old and likely to rip and my way looks cooler.

Besides, hes not going to be racing it at any real tech inspected tracks. Its just a multipurpose offroad toy.

alpha/omega 07-12-2012 09:35 PM

A quick google search found that most all of those flip down brackets are in the $50 range. I think i can build him something cheaper (material + labor)

hav24wheel 07-12-2012 09:59 PM

Piano hinge!


I guess I've never really liked them mounted to the body. Always figured a way to mount them to the carb studs or intake.

alpha/omega 07-12-2012 10:04 PM

Thats where mine is on George.

captain p4 07-12-2012 10:32 PM

I told you that before our epic drunkness, to hinge it. Guess I got your old ass too drunk and you forgot.

ps We're starting at 10 when you get home tomorrow - sleep is for the weak.

alpha/omega 07-12-2012 11:02 PM

Im good with that but i need to take my dog to the vet at some point...i think you gave her gonorrhea of the ear

alpha/omega 07-16-2012 09:35 PM

So Ive finally got a little work out of Paul....

Pulling the 302 for new valve springs to match the e303 cam and a torque converter

http://i253.photobucket.com/albums/h...517_06_02_.jpg

http://i253.photobucket.com/albums/h...-21-10_619.jpg


Overkill x ellebenty seat brackets and install...

1.5"x 11ga square tube and 1/4x2 flat bar. The center is supported with 2 pieces of 1/4x5x5 flat plate sandwiched between the body with 4 - 3/8x1 grade 8 bolts per side.

http://i253.photobucket.com/albums/h...-16-49_730.jpg

http://i253.photobucket.com/albums/h...-16-40_647.jpg

http://i253.photobucket.com/albums/h...-11-37_713.jpg

http://i253.photobucket.com/albums/h...-57-39_240.jpg

http://i253.photobucket.com/albums/h...-18-45_631.jpg

http://i253.photobucket.com/albums/h...2480242288.jpg

Install a-hole
http://i253.photobucket.com/albums/h...-17-47_839.jpg

alpha/omega 07-16-2012 09:37 PM

Poser pic
http://i253.photobucket.com/albums/h...511_39_28_.jpg


Damn, we are some serious bad asses!
http://i253.photobucket.com/albums/h.../IMG956707.jpg

with an impromptu left hand shocker

kjett 07-16-2012 11:12 PM

So are you both trying to take on the badassedness of my bald head and decided to follow suit?

alpha/omega 07-17-2012 07:13 AM

We are bald by choice...

kjett 07-17-2012 07:33 AM

m eh

captain p4 07-17-2012 07:58 PM

That was right before Kris dropped the front hitch on my shin.

drunk em effer!

alpha/omega 07-17-2012 08:09 PM

Waaaaaa waaaaaaaa! :flip:

captain p4 07-17-2012 09:11 PM

a hole! That hurt :(


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