1999 SAS Dana44 ARB 4Runner Build

That suspension sits too tall man. Every time u get slightly off camber your going to crap your pants. I would try and lower it 3 or 4 inches somehow. You must have like 9 inches of lift. Low range offroad only has like 2 inches of lift and cut fenders and they are running 37s. They just cut their fenders a bit.

Hmm, I havent seen anyone with 37" wheels with only 2"s of lift. Could you mabey post a pic of that cause I cant find it. That sounds like a lot of trimming to do. Love the huge truck too keep it up! :)
 
Just for reference for those that may be interested, fullsize Jeep (Cherokee, Wagoneer, and pickup) D44s have the same outers as Chevy for any given year. Brakes, knuckles, spindles, wheelbearing hubs, etc.

You don't have to go to Chevy knuckles for flat tops, though it is nice that the drivers side is already milled/drilled/tapped from the GM factory.

You just have to have pre-78 Chevy or Jeep to get a flat topped passenger knuckle and/or small bearing spindles (useful for vehicles using 5 on 5.5" lug pattern).

That's good information, I'm not an axle expert I was just writing what I encountered. When I bought the Chief Dana44 off craigslist the seller didn't know anything about it other than it was Dana44 with an ARB. It didn't have calipers so when I was going to buy them my buddy told me to verify what the ends were because the Waggy calipers are different than the Chevy calipers. That's when I found out it had Chevy ends. The 80s Waggy Dana44 I tore down for the center housing, not sure of the exact year, had full time 4wd and rounded top knuckles (no flat tops) so we swapped mine onto it. Separating those rusted ball joints wasn't fun, took a sledge to get one of them out, an air hammer got the others out.
 
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Well the beauty with metal is you can cut and reweld most stuff.

Did you call the company and complain about the 3rd member ?

I didn't call the company. It wasn't worth it and the diff didn't fail so they probably wouldn't care anyway. I was just really disappointed that they use a damaged carrier in their product. I just let people know what I experienced and let them make up their own mind if they still want to buy from East Coast Gear.
 
Modifying the Curt Spare Tire Carrier into a drop down carrier.

I have plans to build a swing out tire carrier for my rear bumper but for the meantime I wanted a cheap way to carry my spare. I didn't really want to put in on the roof, the truck is already top heavy enough due to the lift so I decided to get a carrier that goes in the built in hitch in my rear bumper. I found the Curt carrier on Amazon for like $70 but it was solid meaning I would be able to open my rear hatch and that wouldn't work.

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I decided to cut it and weld side plates on it. I then drilled a pivot bold and another hold that took a .5" receiver lock so I could lock it. It does require and anti rattle clamp or the carrier will bounce all over the place. It works pretty well but it's a pain in the ass to lift and lower the tire. I'm planning on building my swing out this winter.

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I also moved my license plate onto an installed a backup camera so I can still see behind me.

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This was the first time I tested the 4WD since I had done the SAS. I was really nervous but the truck did really well. I kept it pretty mild because I was still testing everything. I have since taken it some much more challenging trails and the truck continues to impress me.

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my buddy told me to verify what the ends were because the Waggy calipers are different than the Chevy calipers.

Actually the calipers are the same within any year. 78 and older are different than 79 and newer, however, with the newer ones having metric banjo bolts.

Where did you take it for the shakedown run? Didn't really need 4WD I take it?
 
Actually the calipers are the same within any year. 78 and older are different than 79 and newer, however, with the newer ones having metric banjo bolts.

Where did you take it for the shakedown run? Didn't really need 4WD I take it?

I just took it up to Rainbow Falls in Divide, CO. Nope, didn't really need 4WD, ha ha. It was just to make sure driveshaft angles were OK (I was concerned about the angle on the front, pretty steep), and just to make sure everything else was okay too. Hadn't tested the front axle since swapping everything over like the gears, axle joints, hubs. I wanted to make sure that if something broke a tow truck could get up in there to get me out.

I wish I had pics and video of the last run I took it on. Truck did amazing but that's when it bent my sway bar links.
 
Good to see your getting that monster out in the dirt ! I'm making good use of your old front diff . Thanks for a great deal .
 
Well it was time to add a winch to the front. I did a lot of research and read a lot of reviews and decided to go with the $300 (with coupon) Badlands 12,000 pound winch from Harbor Freight. I know a lot of people with say everything from Harbor Freight is crap but I've been very happy with it. It has tons of power and installed very easily. I don't plan on using it much with lockers front and rear but it's nice to have it as reassurance. Since my truck is pretty tall I see myself using more on off camber trails to give my truck a little more stability. Since my truck sits outside a lot I didn't want to use synthetic line.

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Lockers front and rear have the capability to get you in tighter jams than having open diffs front and rear. Thinking those are going to save you from needing a winch either shows inexperience or a lack of pushing the rig to the potential it has (or a bit of both).
 
I did install wheel spacers on the front. I used the 1.25 spidertrax. The 35" tires might have fit without them but I didn't want to take the chance of cutting into the sidewalls.
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Lockers front and rear have the capability to get you in tighter jams than having open diffs front and rear. Thinking those are going to save you from needing a winch either shows inexperience or a lack of pushing the rig to the potential it has (or a bit of both).

It was supposed to be a joke. Maybe I should have put ha ha or lol. Obviously I understand the importance of a winch since I installed one, there are a lot of trails that you simply can't get over certain obstacles without a winch, especially here in Colorado. Thanks for your opinion though.
 
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Lockers front and rear have the capability to get you in tighter jams than having open diffs front and rear. Thinking those are going to save you from needing a winch either shows inexperience or a lack of pushing the rig to the potential it has (or a bit of both).

Am I missing something here? I have a winch, been on my truck 15 years or so, never needed it for myself. I've been wheeling the same truck for 19 years, and I've pushed it plenty, but never beyond my comfort level. I owned a body shop for 14 of those 19 years and I still have a point at which the body damage isn't worth doing the trail to me. The reality is, I don't need a winch, as I'm now seeing the half century point in my rear view, I need it less and less. ARB's have done fine for me. Does feel good to have the insurance though.

And I've used it to winch lot's of other folks out of their self induced predicaments.

The above comment reeks of Pirate 4x4 chest thumping though. Why is that necessary? My apologies to the author if I am misunderstanding. I do know that I don't know, or understand everything.
 
Pirate 4x4 chest thumping is a bit much there Iball. I've never been a chest thumper and if there was any of that, it's long gone as I too am approaching that half century mark. I push my rig past my comfort level for a feeling of accomplishment, not for anyone else's approval or for bragging rights. The tub of my CJ5 is about to literally tear into two pieces, due to my lack of concern for body damage and willingness to pull cable if I fail.

A rig such as the OP has built is just asking to be wheeled hard past the comfort level or it was just a waste of time, IMO. Sometimes you have to just try a hard line instead of just taking the ones you know the rig can complete. If you're not comfortable with that approach, so be it, no skin off my back. It's all wheeling.
 
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Pirate 4x4 chest thumping is a bit much there Iball. I've never been a chest thumper and if there was any of that, it's long gone as I too am approaching that half century mark. I push my rig past my comfort level for a feeling of accomplishment, not for anyone else's approval or for bragging rights. The tub of my CJ5 is about to literally tear into two pieces, due to my lack of concern for body damage and willingness to pull cable if I fail.

A rig such as the OP has built is just asking to be wheeled hard past the comfort level or it was just a waste of time, IMO. Sometimes you have to just try a hard line instead of just taking the ones you know the rig can complete. If you're not comfortable with that approach, so be it, no skin off my back. It's all wheeling.

I'm good with all that, just sensed a bit of tone maybe you didn't mean to deliver. I pick the hard line too, and I've ripped the CJ5 off it's mounts too. My old dog, gone now, used to look at me sometimes as if to say, enough already!
Sometimes the hard line is not for me. But I've pulled line and broken parts, mostly on other's rigs but mine too. I just want to enjoy getting back to camp, or TO camp with my beer and all of my friends, AND their trucks. Eventually I'll give the FJ62 to my son, and the 3rd gen will be more overland, with the capability to crawl, sometimes. Damn all this talk is making me want to get out there!
 

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