We were talking in the other thread about a SAS on the GMT 800. I did a search and didn't really see any how-to's, just a few guys saying they had done them, but not much.

The kits I see currently are the Sky's Off Road Design, using 99-04 Ford F250 Super Duty Dana 60. And the OffRoad Unlimited using 77.5-79 Ford Dana 60. I think both kits use Square Body generation leaf springs.

@arthursc2 mentioned the abs tone ring is different on the Fords. Those websites don't mention anything about that. And using the Dodge solid front axle is a viable option. That's the AAM 9.25", right? And lug nuts match the GM? What locker is available for it? I "think" the Power Wagon has a factory e-locker? 🤔

I'd like to learn more...

 

Are you doing this in a 1500 or a 2500?

WFO make a kit for the 2500's they also have the conversion for the tone ring.
https://www.wfoconcepts.com/p-35853-solid-axle-kits.html

Offroad Unlimited has some kits.
https://www.offroadunlimited.com/cat...conversion-kit

Pirate 4x4 has a bunch of builds too...

 

This is my favorite SAS... He open sourced and shared the files with everyone. Delta Vehicle Systems can cut bend and ship the kit.
https://www.pirate4x4.com/threads/mu...build.2379705/
https://www.deltavs.com/all-products...olid-axle-swap

 

Thanks. I'm just brainstorming at the moment. ☺️ But it would be a 2500.

 

Then you will enjoy that build above. It's very detailed!!!
There is plenty of other SAS swaps on pirate but That's the most detailed one.

 

The Dodge axle is an AAM 9.25. There are factory e-lockers available for it in the front of the Power Wagon and in the rear of the H2. Since Power Wagon axles are so expensive, I bought a $300 front axle from the yard, a $450 Hummer axle, robbed the locker and shafts and scrapped the rest. After buying 4.56 gears, I will have a "Power Wagon" front axle for ~$1200

I am using an '08 axle. Its currently open and 3.73. I will probably leave it 3.73 and open until I have the axle hung, shaft made and have all the kinks of the build worked out, then drop it off at a gear shop to get regeared

Radius arms > leafs, all day. Radius arms with OE coils and shocks or coil overs, but f*** leafs

Our steering box is wrong, so I am going to do a Ford or Dodge box about it, and I know I will have to modify the frame for either one. You might be able to leave our pitman arm the way it is and sneak the steering link around the panhard bar, but I wouldn't count on it. I am going to get a box from an OE solid truck and party with that

I also plan to run 35's and will be pushing my front axle forward ~4" to accommodate that. I am not yet sure how many frame mods will be needed to be made to make that happen, but the diff should be well clear of the oil pan at that point

From current ride height on 33s to SAS on 35s, I am planning on only gaining 5" of height. We will see if that is possible

 

WOW! That sounds like a great plan! I have read something about the H2 e-locker being interchangable with the Power Wagon axle.

What is wrong with the GM gearbox? Is it too weak?

I had thought of buying a Cherokee XJ to mess around with my son as a project. LS swap it, etc...a lot of work and money. Maybe a SAS on my truck is cheaper/easier. It already has the LS and 14 bolt. I'm thinking mild off-road, nothing wild. 🤔

 

Our pitman points the wrong way, and you can't just flip the arm because then left becomes right lol. You might be able to swap gears/sector shafts to fix that. I haven't actually looked. Not entirely sure what other SAS guys have done, no one seems to have an issue that they post about so maybe I am making a mountain out of a mole hill

 

Pitman arm points the wrong way for what?

The guy I posted up used a ford axle and even moved the centerline forward a few inches to clear 37 and still used the OE Box with a different arm.

 

Our arm points toward the back of the truck, instead of toward the front of the truck, and depending on how you route links and mount your panhard to the frame, might cause issues with link clearance

Most OE solid trucks have a steering box that points the arm forward, making for much better clearance on the panhard and makes the drag link colinear (ish) with the front of the knuckle, so you dont run into turning tighter one way than the other

Like I said, since you are captain technicality today- is that no one seems to have an issue and I might be making a mountain out of a mole hill