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SAS SUA on a 1994 Nissan
WD21 Pathfinder |
Updated 1/14/2010 |
The plan: SUA Leafs with a 1984 Dana 44 jeep wagoneer axle.80-92
will work. All are disc brake drivers drop.
Specs
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CALMINI hangers front and rear
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Rancho 44044 leafs
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lockright rear locker
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4.56 gears,to match Nissan 4.6 in the H233b - stock was 4.3,
now installing 4.9s.
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custom driveshaft adapter with CV up front all 1310
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14" travel shocks.
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33" tires
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15x8 rims
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1.5" DOM steering with tres
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NissanNut shock towers.
The Pathfinder already has a 3" BL and UCA lift and
lower 4.6 gears and rear lockright..
stock
after
4wd
Plan 33" tires, 4.6 gears,
spring under axle with a shackle
reversal.
Material List spreadsheet.xls
Action plan:
order all parts
rebuild axle as needed.
install locker and 4.56 gears
install frt hanger / relocate front bumper
install rear bell shackle kit
build shock towers
build / order tie rod and drag link
cut off ifs / hang axle connect brakes steering and shocks
modify crossmember
modify exhaust
install / make frt driveshaft
sway bar install - done
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This page is broken into sections:
- Axle Prep
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Ball joint install
-
wheel lug and rotor install
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lock right install
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dana 44 gear install
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assemble axle
- Front spring hangers/shackles
- Deconstruction
- Shock towers
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Steering and steering stabilizer
- Front brakes
- Front Driveshaft
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Sway bar
- Transmission cross member mod
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Y pipe mod
- Material list
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Axle prep |
This is the donor axle straight
from the junk yard. All parts were taken apart and cleaned and painted.
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Ball joint install |
Starting with clean empty
knuckles. Press in the lower balljoint first. Then the top.
Already to install on housing and torque to spec with the
special tool.
First install the lower nut. The sleeve. Then upper nut.
Torque the lower then the sleeve, then the upper nut.
Now install the new spindle bearing.
Now install rear new wheel bearing race and seal. I used
old races as spacers to pound in new. I grinded down like a setup bearing.
Pound out the old and pop in the new.
Install the small front race. I used slug as a spacer.
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Wheel lug and rotor install |
Starting with new lugs and rotor and old hub. Press the
lugs through the rotor into the hub. I made a spacer to help the install.
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lock right install |
To install the lock righ locker in the new 3.92 carrier. You need the side
gear shims from the old carrier. To get the shims do this. Remove the ring
gear bolts. Toss the ring gear in the ebay pile. Using a 3/16 punch from the
bolt side push the lock pin out.
Now pound out the spider gear pin with a big punch. All the spiders and
side gears just fall out now. Save only the two shims behind the side gears
for the lock right install.Now press off the bearing with a bearing splitter
($9 Harbor freight) and a 2 jaw gear puller. I put a Nissan torsion bar
washer in the hole. I want the old carrier bearing shims to set carrier
preload and I will make setup bearings with the old ones. Keep track which
shims come from which side of carrier.
Now press the old pinion bearing off so You can make another setup
bearing. I used the same splitter and a press this time. Now you can junk or
sell the 2.72 carrier, carrier pin, gears and spiders. LAst pic is the good
stuff to keep for mockup and spares.
OK now ready to start the lock right install in the new carrier.
Now ready for ring and pinion. |
dana 44 gear install |
First step: Make setup bearings. I used the old carrier bearings and the old
lower pinion race.
I then installed the axle tube seals. Then installed the pinion with the
setup bearing race. There is allot of trial and error setting up gears.
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Assembly of
axle. |
Install axle shafts. then install seals. Then install spindle and caliper
bracket.
Slide on completed hub assembly. Install small bearing, locknut, washer and
locknut. Torque to 50lbs with another special tool.
Install brake caliper and pads. Dont forget the little clips.
Install manual hub.
Axle is ready to be installed
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Front hanger |
First step was to remove Winch bumper and
brackets. Then cut off the OEM tie downs flush with the frame. Click on the
pictures for notes.
Then add some tacks. And reinstall the bumper.
This is the after re adding the original KMA bumper bracket as a gusset. We
added the piece removed from first picture above.
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Rear shackle mount |
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Front driveshaft |
Decided to use the stock frt driveshaft from a
D21 with a CV. The WD21 does not use 1310 U joints like D21s do.
More details here: |
Deconstruction |
My biddy came over at 7am and we cut off the front end. Instaled the leafs
in the hangers we installed weeks before. Cut the drag link to length for
the steering. ended up being the same specs as the other suspension styles.
Had an issue with one of the calipers, cut a hard line with the sawzall. And
the wheels did not clear the calipers. So did not get to test drive. But a
SAS in one day is possible with proper planning.
SAS day, See more here.....
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Shock towers |
Made some tower from 2x2 .120 wall. Added some tabs.
Shockes 11-12" work best. These were 14" travel so it was harder to get them
to fit.
Updated; I arched the tower out and made the removable mount better with 2
bolts.
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Steering |
Steering is typical DOM with 7/8 TREs. Used weld in bungs
instead of tapping threads. The Pitman arm is reamed to accept larger TRE.
Update: We moved the TRE above the pitman. This is for more sway bar
clearance and up travel.
More steering details here. |
front brakes |
Install stainless Earls brake lines. All 10mm.
Banjo at caliper. For front brake lines I
bought these from Summitracing.com
24" long 10mm to 10mm. Nissan and Dana 44 axles (gm/jeep calipers) use
10mm.1980+ are all 10mm. Just like Nissan. If You already have longer
aftermarket brake lines they will work.
Part # Item Price Qty Price
EAR-63010124ERL -3 ST./ST. 24" HOSE $12.88 2ea $25.76
EAR-989545ERL BRAKE ADAPTER -3 TO 10MM F I.F $4.99 2ea $9.98
EAR-997631ERL BANJO -3 TO 10MM $7.39 2ea $14.78
Parts Total: $50.52
You can save a few bucks by using shorter lines. These are quite long.
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2wd test drive |
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Sway bar |
Moved to SAS sway bar page |
Trans cross member mod |
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Bump stops |
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Done!!!
More flex pics.
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