Chevy & GMC Vans

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.

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.

Now for more pics of the SAS!

Front crossmember



Getting started

Hanging the front leafs







Test fitting the axle

Now the rear axle

Mostly finished product!

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

Oh great Keith now we are going to have to make wider door ways for Dean to get through.

lol

Fire Cakes wrote:Oh great Keith now we are going to have to make wider door ways for Dean to get through.

What does she mean by that?

LOL. Every time I see this I am amazed, and the temptation of doing something similar makes my pocket book ache.

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.

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

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.

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.