Solid Axle Swap into a 1998 Astro AWD
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Topic author - 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
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"
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.
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"
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.
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
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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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
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.
I also converted this rear to disc brakes using a bolt-on bracket and some 1979 Chevy K20 calipers, pads and rotors.
I also converted this rear to disc brakes using a bolt-on bracket and some 1979 Chevy K20 calipers, pads and rotors.
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
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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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
Now for more pics of the SAS!
Front crossmember
Getting started
Front crossmember
Getting started
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
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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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
Hanging the front leafs
Test fitting the axle
Test fitting the axle
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
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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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
Now the rear axle
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
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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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
Mostly finished product!
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
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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- I sleep in my van
- Posts: 306
- Joined: Sat Sep 09, 2006 3:16 pm
- Location: New Haven, NY
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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
What does she mean by that? [-XFire Cakes wrote:Oh great Keith now we are going to have to make wider door ways for Dean to get through. :-k ](*,)
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
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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- I plan to be buried in my van
- Posts: 1290
- Joined: Sat Sep 09, 2006 7:14 pm
- Location: Exeter ON
- Contact:
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/
Jim
1997 GMC Safari RWD, Power Windows and Locks, 7 passenger, a/c, rear heat
http://rileysowner.blogspot.com/
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- I get chills without my van.
- Posts: 52
- Joined: Sat Sep 09, 2006 5:32 pm
- Location: Berlin, WI
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.
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.
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Topic author - I have my van tatooed on my cheeks
- Posts: 4379
- Joined: Sat Sep 09, 2006 3:35 pm
- Location: New Haven, NY
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
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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- I get chills without my van.
- Posts: 52
- Joined: Sat Sep 09, 2006 5:32 pm
- Location: Berlin, WI
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.
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.