SAS discussion on alternative axles

Toyota231 · May 29, 2024

I've got an '89 k2500, looking at doing a SAS on it but I'm thinking about using either a 99-04 superduty 60 or an 04+ superduty 60. So I would like to see if anyone has done a SAS with either axles? I know Sky off road makes a hanger kit for the 99-04 axles but i don't care for how far it hangs down in the front much more than i like. I'm curious as to how hard the ORD hangers would be to modify for the wider 37.5" spring perch width. But I'm also curious to see if anyone has ever used the coil spring 04+ superduty 60, and used the coil springs and radius arms, but I'm not sure on all the measurements lining up closely. Now i have a huge background in doing SAS's on toyota's and other's but never done anything on a gmt400. So if anyone has any experience lets talk.

b454rat · May 30, 2024

ORD makes top notch stuff, modifying it will pretty much be cutting them up n starting over. It's tight to begin with on the rear hangers, it's even worse with the wider perch width. WFO makes the kit to use the coils, but it ain't cheap. I guess maybe it an even difference, early stuff is semi expensive, newer stuff is cheap. Too bad weren't closer, I have 2 HP 60s from late 80s to early 90s Im not gonna use....

AirMdwn · Jun 29, 2024

I haven’t done a 99-04 swap but I think the reason most dont use that axle is because the tires rub the springs, reducing steering angle and the rear hanger would run into the frame and the frame would need to be notched for clearance. I believe I saw someone on another site used the 05+ axle with the arms, coil springs and welded on frame buckets. But the radius arm mounting had to go out side the frame and there were clearance/packaging issues. Doable, but not perfect.
If you’re looking for other axle options, the 92-98 ford D60 is the same thing as the 88-91 D60, but the later axle has ball joints. Both leaf spring and a narrower spring pad width compared to the 99-04.
Choosing an axle and suspension kinda depends on what you’re trying to do with the truck. Hardcore crawler, mud digger, overlander, fire roads/camping. What did you have in mind? The GMT400 platform is kind of limited unless you’re planning on full fab work. In that case, **** yeah I’ll help you spend your money

b454rat · Jun 29, 2024

Only negative bout the ball joint axles is inability to go crossover steering. I guess there are kits out there to weld onto the knuckle, or maybe machining it for an arm. I'm not going that route, or ever, so not really too concerned bout it. There are still plenty of other axles to use....

AirMdwn · Jul 7, 2024

^Yup, plenty of other axle options too, the D44, the D30.
WFO sells a kit to swap the 05+ axle with radius arms and coil overs

CumminsFever · Jul 8, 2024

I notice "everyone" uses the ford axles for the solid axle swaps. That seems to be the popular thing anyway. Could any one of you guys explain why the ford axle is the popular one?
Older chevys used the dana 44, wouldn't that work for street or mild off-road? Why not the dodge dana 60?
I'm not doing a SAS, just trying to learn!

Nad_Yvalhosert · Jul 8, 2024

CumminsFever said:
I notice "everyone" uses the ford axles for the solid axle swaps. That seems to be the popular thing anyway. Could any one of you guys explain why the ford axle is the popular one?

Dodge pre '94 and GM pre '88 Dana 44 is a pass side diff. Ford uses a driver side diff. GMT400 is also driver side diff

CumminsFever said:
Older chevys used the dana 44, wouldn't that work for street or mild off-road? Why not the dodge dana 60?
I'm not doing a SAS, just trying to learn!

Opposite side pumpkin requires 2 to 3 times more fabrication.

A:
Completely redesign the entire exhaust system so the front driveshaft can be installed without interference (not legal in CA)

B:
Gut the interior, fill the driver side hole once used by the OE t-case shifter, find/cut floor/mount a pass side t-case shifter, probably a new carpet.

C:
Locate a pass side drop t-case that is compatible with the VSS if you want the speedometer/RWAL to operate.

D:
Two new driveshafts instead of just one

Nad_Yvalhosert · Jul 8, 2024

@CumminsFever
There's also the frame width to keep in mind. Trying to line up the coil spring pockets from a wide frame Super Duty or late model Ram,
onto a narrow frame GM takes even more skill.
Then there's crossover steering linkages and available parts... you'll need to be a measuring master and a parts store catalog explorer to cobble a system together. Or a genius welder?

Lastly, wheel bolt patterns:
GMT400 8x6.5
Super Duper 8x170mm

Planning on carrying 2 spare tires?

CumminsFever · Jul 9, 2024

Nad_Yvalhosert said:
Dodge pre '94 and GM pre '88 Dana 44 is a pass side diff. Ford uses a driver side diff. GMT400 is also driver side diff

Opposite side pumpkin requires 2 to 3 times more fabrication.

A:
Completely redesign the entire exhaust system so the front driveshaft can be installed without interference (not legal in CA)

B:
Gut the interior, fill the driver side hole once used by the OE t-case shifter, find/cut floor/mount a pass side t-case shifter, probably a new carpet.

C:
Locate a pass side drop t-case that is compatible with the VSS if you want the speedometer/RWAL to operate.

D:
Two new driveshafts instead of just one

Well, i admit, it's been that long since I crawled under an older truck that I forgot about the passenger side driveshaft. Thanks for the explanations, it makes sense!

b454rat · Jul 9, 2024

Exhaust has to be mod'd regardless of what axle to use. The hangers are the same, just the drop of the axle.

SAS discussion on alternative axles

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