Solid Axle Swap into a 1998 Astro AWD


Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Solid Axle Swap into a 1998 Astro AWD

Post by LiftedAWDAstro »

First I will give what axles I used and what will/should work.

Front axle: Basically any Ford truck solid axle will work if you want to keep the front diff on the driver side like it is setup in a stock AWD van. The axle I used is from a 1979 F250 and is a Dana 44 HD and is built as a high pinion. This axle is desireable as it has 1/2" thick axle tubes, is full width ~68" or so and is configured as high pinion which puts the centerline of the pinion above the centerline of the diff. This gives better clearance and driveshaft angles. This axle was also setup as a stock leaf sprung axle whereas 1/2 ton axles are all coil sprung and radius arms unless found in a 1/2 ton supercab truck. Bolt patterns are 3/4 and 1 ton: 8 x 6.5" and 1/2 ton: 5 x 5.5"

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I also converted the steering over to high steer which puts the steering tie rod and drag link well above the leaf springs and up out of harms way. I used Parts Mike parts for this conversion.

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Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

Rear Axle: For the rear I wanted to keep with the 8 lug pattern I had on the front so I knew I needed a 3/4 or 1 ton axle and also needed an axle with an offset diff since I wasn't moving the stock fuel tank. I found an axle out of a 1990 Ford E-250 van which was a Dana 60 and was already setup with 4.10 gears. This is also a full floater axle which is a better design for wheeling.

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I also converted this rear to disc brakes using a bolt-on bracket and some 1979 Chevy K20 calipers, pads and rotors.

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Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

Now for more pics of the SAS!

Front crossmember

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Getting started

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Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

Hanging the front leafs

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Test fitting the axle

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Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

Now the rear axle

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Last edited by LiftedAWDAstro on Sat Sep 09, 2006 7:34 pm, edited 1 time in total.
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

Mostly finished product!

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Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

astrozam
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Post by astrozam »

Excellent info Dean, this type of post is gold, it really helps in understanding what a person has done to their van, nice job.

Fire Cakes
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Post by Fire Cakes »

Oh great Keith now we are going to have to make wider door ways for Dean to get through. :-k ](*,)

astrozam
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Post by astrozam »

lol

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

Fire Cakes wrote:Oh great Keith now we are going to have to make wider door ways for Dean to get through. :-k ](*,)
What does she mean by that? [-X
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy
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Rileysowner
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Post by Rileysowner »

LOL. Every time I see this I am amazed, and the temptation of doing something similar makes my pocket book ache. ](*,)
"I have a torque wrench and I am not afraid to use it."
Jim
1997 GMC Safari RWD, Power Windows and Locks, 7 passenger, a/c, rear heat

http://rileysowner.blogspot.com/

jakepatch
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Post by jakepatch »

Great info Dean, thanks for bringing it over to this site.
I am currently in middle of a similar swap, but haven't posted on AS.com because of the problems with posting.
I went a little different route, I am using axles from a 1986 Jeep Grand Wagoneer. They are 4 inches narrower than the Astro, but with the right offset wheels, I'll be able to run bigger tires and still keep them tucked under the van. Currently I have cut off all the IFS from my subframe, now time to start taking measurements to make the new brackets. I'l try to have some pics and a decent write-up when finished.

jakepatch
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Post by jakepatch »

Oh, yeah, by the way the front axle is a Dana 44, the rear is a Mopar axle, not sure what it is.

Topic author
LiftedAWDAstro
I have my van tatooed on my cheeks
Posts: 4379
Joined: Sat Sep 09, 2006 3:35 pm
Location: New Haven, NY

Post by LiftedAWDAstro »

C'mon Jake! You gotta post some pics! BTW the rear axle in the waggy should be a D44 as well unless it was swapped at some time.
Current rides:
2013 Toyota Tundra DC 4x4
2008 Dodge Nitro 4x4
2005 Nissan Sentra 1.8S Special Edition

Mileage spreadsheet

Vans owned:
1986 Safari 2.5L 4 speed manual - scrapped
1995 Astro 2WD conversion 4.11 posi, shift kit, DHC rock rails - sold to Skippy
1998 Astro 4x4 D44, D60, NP231, full hydraulic system with 9k# Milemarker winch and snow plow - sold to Lockdoc
2003 Astro AWD all stock - traded for a 3/4 ton truck
2005 AWD, 4.10's - sold to skippy

jakepatch
I get chills without my van.
Posts: 52
Joined: Sat Sep 09, 2006 5:32 pm
Location: Berlin, WI
Been thanked: 1 time

Post by jakepatch »

Rear is Mopar, I'm just not up on Dodge parts to know what it is, and haven't looked to find out.
The router for my computers died, so I am down to just the wife's computer online right now. Gotta get mine back up and going to be able to post pics. Too much involved to do it all on hers. Hopefully soon.
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