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Old 08-20-2016, 03:17 PM #16
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I found an incredible deal on Craigslist. I found a Dana44 out of a Cherokee Chief with an ARB airlocker, already converted to high steer with Chevy ends for $450. The guy who had it didn't know what gears were in it.

I was even more excited when I got it home and realized it had 4:88 gears already installed in it. What an incredible find.





My dog likes to help out when he can.



Axle all cleaned up with new rotors, lugs, and wheel bearings repacked with grease. You have to love a supportive wife.




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Old 08-20-2016, 03:20 PM #17
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I went with Trail Gear's heavy duty single transfer case crossmember. Sent it off to get powder coated satin black. It looks awesome but my wife isn't really a fan of it sitting on out kitchen table. I think it looks good there.

This crossmember's are super heavy duty, like .5" thick steel. I can't see it getting damaged on the trail.


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Old 08-20-2016, 03:24 PM #18
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Decided it was a good time to do some maintenance before starting the SAS. Went and did the timing belt, water pump, hoses, belts,plugs, and wires.





Last edited by Mountain Fun; 08-23-2017 at 09:18 PM.
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Old 08-20-2016, 03:36 PM #19
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I'm a little confused. Why are you spending money on a lift and front diff when your doing a SAS up front ? Sick build bro!! Looking forward. Liking how the progress is going fast

( it amazes me that people don't reply to this thread. If it was about a TRD STICKER it would be pages long lol)
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Old 08-20-2016, 03:47 PM #20
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I wanted to talk a little bit about cost of doing an SAS on a 3rd Gen 4Runner. I read a lot of crap online about guys doing an SAS anywhere from $600 to $2000. This is total bullshit, there is no way you can do this and still have a drivable safe truck. If you do the work yourself you are going to spend between $5000 to $8000 depending on how much you junkyard your parts. If you hire a shop to perform your install add about another $2500 to $4000 depending on the complexity of your install. I decided to buy new parts for everything except the front axle housing.

This is a brief breakdown of some of my cost:
Front SAS kit from Sky Manufacturing: $3000
Rear leaf kit and shock hoop: $800
Crossmember with powder coat: $500
Addicted Offroad bumper package: $1600
Powder coat for bumpers: $500
Rear driveshaft: $120
Front long spine driveshaft: $500
Front Axle used: $450
Front Axle parts: $250
5 37" tires and wheels: $2500
Rear spare tire carrier: $200
Welding wire and supplies: $100
Grinding pads and cutoff wheels: $150
Gear lube, oil, powersteering and brake fluid: $200
Misc expenses: $250
Parts shipping cost: $600
Rear ARB airlocker new on craigslist: $600

I'm sure I forgot some things but this will give you a pretty good idea that's not a cheap date.

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Old 08-20-2016, 03:52 PM #21
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Quote:
Originally Posted by kolelt View Post
I'm a little confused. Why are you spending money on a lift and front diff when your doing a SAS up front ? Sick build bro!! Looking forward. Liking how the progress is going fast

( it amazes me that people don't reply to this thread. If it was about a TRD STICKER it would be pages long lol)
Initially I didn't plan on doing an SAS. I was just going to do the 5" lift with 35" tires and keep it somewhat tame. But after tearing through 3 CV boots up front and a reoccurring from diff leak that would splatter everywhere I got frustrated to the point where I said screw it and decided to SAS. I'm so glad I did it. The truck is my dream truck. The build is completely done now, I'm just trying to find the time to write the entire build. I just want it to help people if they decide to SAS so they don't make some of the mistakes that I made.
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Old 08-20-2016, 03:57 PM #22
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Starting the SAS 1999 4Runner with a Waggy 44

I decided to go with the Sky Manufacturing SAS kit (unfortunately it's no longer available as a kit but most of the parts are still available just sold individually). It was an awesome kit, high quality brackets and parts. It's supposed to be a 7" lift kit but I think it came out closer to 9". Came out a little taller than I wanted but I'm still very happy with it. Only problem is no instruction so you spend a lot of time mock fitting and measuring with a tape measure. The crawler springs is came ride very well and provide insane axle articulation (pictures to come later in build).

I just wanted to add that the guys at Sky Manufacturing were awesome. They answered my questions for my about the kit, my brakes, and other concerns I had. There products are bad ass and custom built. Here is the link to their page if you wanted to see their products:
Sky's Off Road Design – Sky's Offroad Design


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Old 08-20-2016, 04:16 PM #23
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My first potentially big mistake! I measured the Cherokee Chief Dana44 as 60" WMS (wheel mount surface) but I was measuring from rotor to rotor, not WMS to WMS. The Chief Dana is about 3" wider than the Wagoneer Dana. Not only would the front axle be 3" wider than the rear but none of my high steer parts would fit this axle. This could have been a huge problem but luckily a good buddy of mine had a Wagoneer Dana44 axle that had been sitting for like 20 years that he sold me for $150. It took about a days work to swap everything over and brake down and reassemble the axle shafts but it all worked out in the end. I have to thank Josh for helping me out of this one.












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Old 08-20-2016, 04:24 PM #24
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Addicted Offroad front and rear bumpers

I decided with the built to get rid of the crappy cosmetic factory bumpers for some real trail armor. I decided to go with Addicted Offroad's tube bumpers and rock sliders. They are bad ass, super strong, and an incredible value for the money. Only negative is be prepared to wait 2 to 3 months once you order them. Mine took 3 months to get. The reason this was big pain is that I needed the front bumpers crossmember mount to start my build. I was going to weld it to my frame and then weld my spring hangers to that. Still worth the wait though.

I had them powder coated satin black.




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Old 08-20-2016, 04:32 PM #25
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Well it was time to start the build. I had taken several welding classes in preparation but was starting to get nervous about taking this on in my small one car garage. I went to a couple of local shops and got quotes from them on the install which ranged from 20 to 40 hours at shop rate, basically $3000 to $4000. It was important to me that I did the build myself so I was bracing myself to do it in my garage when my buddy Josh volunteered to help and said we could use his garage. This was huge because not only had Josh already SAS his Tacoma but his garage had a full lift, every tool you can imagine, and a killer 220v miller welder. It took the two of us about a combined 50 hours to complete the build. I can't thank him enough for all his help and knowledge.
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Old 08-20-2016, 04:46 PM #26
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Pulled the truck into the garage, when it backs out of this garage it will be SAS and leaf springs front and rear.



We attacked the front end first cutting out all the factory bracketry and grinding it down to a smooth frame.









Crossmember was mocked into place for welding it in.


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Old 08-20-2016, 04:53 PM #27
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Deffinatley JELOUS. Badass truck sir. And definitely a lot of $$$$$$

I believe there is a member on here who is owner of SLAG FACTORY who did a sick job on SAS conversion.
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Old 08-20-2016, 04:56 PM #28
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Drivers side done and frame brace welded in.



Addicted Offroad's bumper crossmember getting ready to be welded in place.



Front axle completely assembled and sanded smooth ready for install.


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Old 08-20-2016, 05:01 PM #29
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I haven't heard of sky manufacturing before I'm glad I have now, just looked at their site and might be ordering stuff for future projects.
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Old 08-20-2016, 05:17 PM #30
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The oil pan had to be switched over to a rear sump to make room for the high crossover steering.

**I forgot initially to mention a very important potential problem. The dipstick! I was lucky enough that the 1999 4runner had a plug in the block that can be knocked out to install the rear sump dipstick tube. Later model do require drilling out the block (at an angle from the bottom) for the dipstick tube. This is why Trail Gear just has you cut the dipstick down and add an extra quart of oil. I did this on my front original dip stick and left it where it was but I did install the rear sump dipstick also. The second problem I ran into is that my motor mount didn't have the hole for the tube (some models do, my friends Tacoma had the hole in the motor mount) but we had to pull off the motor mount and drill a large hole in it for the dipstick to go through. Not a huge problem but did take a couple of hours to complete.



I don't have any pictures of this but the drivers motor mount had to be removed and drilled out to make room for the new dipstick. There was also a plug that was knocked out of the bottom of the motor for the dipstick tube.





This was by far the scariest part of the install. Huge pieces had to be cut out of the frame behind the motor to make room for the frenched shackles. If we screwed up here it would be very hard to repair. I'm sure Sky Manufacturing has a jig they use when they are SASing trucks but we didn't have anything like that. To make it even more complicated the frame is angled in here so you are cutting this piece out at an angle.






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