As some of you guys know, I had the SLR 5inch lift on order. After patiently waiting for months, the high price of the lift started to settle in. I had plans for a SAS down the road, so why should I pay for an expensive lift now. Thanks to some other members in RMXC, I came across a great company in Colorado, All Phase Offroad. I decided to take my truck and and get a quote on a SAS. The next day I got a quote on parts that were the SAME price for the SLR lift. Don't get me wrong, SLR will have a great lift out, but after seeing the parts price being the same, I took a few days to think this SAS over. Eventually I decided to go ahead and proceed with the project.

Part's List:
Dana 44 - Ford Bronco 78-79
Dana 44 4.56:1 Ring and Pinion
Dana 44 Master Install Kit
Ford 9" - Ford Bronco 78-79
Ford 9" 4.56:1 Ring and Pinion
Ford 9" Master Install Kit
Detroit Locker
Bronco Monster Radius Arms - High Travel
Fox 2" Coilovers - Emulsion
King 300lb Coil Springs
Rebuilt Steering Box
Custom Tie Rod and Drag Link
Pittman Arm
Ford Radius Arm Clamps
Custom Front Track Bar
Steering Shaft
Steering Stabilzer
Bilistien Shocks - Rear
Misc Front Axle Parts - Brakes, Brake Lines, etc.
Custom Hydraulic Steering Lines
Custom Front Bump Stops
Custom HD CV Drive Shaft
Custom T-Case/Tranny Mount/ Skid
Misc Parts for Rear Spring Over
Custom Front Skid Plate

With the help of some RMXC members and AK9849CY (pathfinder owner), we located and pulled the axles. AK9849CY found them for $60 an axle, it was a great deal.

Front Dana 44


Rear Ford 9" Heavy Duty


The Dana 44 cleaned up nicely.


Time to get the X on the lift and start gutting. The tire location and height from the lift is an estimate of ride height.

Few more pics:
The spring perches on the ford 9" matched up to the nissan springs in the rear. Things could not have gone smoother. Lets hope it stays this way.





The rest:
http://alpinetribe.com/Gallery/SAS

One thing we did find on the IFS, is that the alignment bolts on the control arms were stripping. Seems these bolts will NOT hold up to the punishment of offroad abuse. For those of you that wheel your 2nd Gen xterra, you WILL eventually break these bolts sooner than later. Im sorry, but I forgot to take pictures of the damage on the bolts. I will remember on Tuesday and get the exact location so you can check yours.

holy shit!! more pics! more more!!when do you think you'll be all done with it? and maybe i missed it, but what size\type tires are those? oh and did i mention, dont forget more pics! that is gonna be such a badass truck when its all done

So whats the deal?!?!? I drove 90 (one way) miles to help you pull that 9" and it still looks like crap?!?!? Geeez man no respect... no respect.

Just kiddin... I will be down Tuesday to help the guys out some.

You're my hero. I hope it continues to go smoothly. You're certainly a pioneer now ..

Not sure how long yet, we are aiming for the beginning of April. The tires are 36x13.50 IROKs on 15x10 Steelies. I decided to change the rear end because of the larger tires. For one, there is no gears for the 05 yet, and I don't want to chance 36s on the stock axle.

You are also my new hero too. Looks Sweet man, cant wait to see the end result.

nice! yea i remember somewhere reading that the stock 05+ axles may only be able to handle up to 34 or 35" tires, but the tires and rims look great! really can't wait to see it all done

YOU ARE A HOMO!!! And as others have said my hero
DAMN I wanna SAS SOOO BAD, but I must be patient.

Pony it looks great.

Nice work.

Post more pics and let us know how it turns out. I guess this is proof that if you want something bad enough then why wait for company "A" or "B" to make it for you.

If you don't mind please post your final costs too.

Wow. Looks great. I think you may void the warranty.

Out-fricking-standing!

Going to goneMoab?

-Doug

As soon as its finished and cost is finalized, I will be sure to post the price.

You bet ya.

Holy crap! That takes nuts to do to such a new truck.

You're my hero as well.

That's what I sayin! Nothing like taking a brand new $27,000 truck and hacking the underside of it off and customizing your own version.

You got balls...I like balls (Team America reference).

I said it before, and I'll say it again...
Bad
Ass
Truck

That night be the only 2nd gen that trully deserves the offroad emblem

Looks awesome so far..

Looking good...

Keep going don't let up.............

I hope this continues to go smoothly for you. I can see All Phase Offroad getting some business out of this one if all goes well. The choice to go with the 9" in the rear was wise, wide range of low cost gears available.

Can't wait to see the progress and even more so the results.

Thanks for posting this.

This coming from somone that owns not one, but TWO Xterras with about every mod available short of a solid axle...

with a 'wondeful' colour scheme at that :rolleyes: ...nah, they look sweet Dagger..... but I this might be the best yet....wow Ponyboy, looks awsome so far!

Impressive. Those axles would be way too wide for a 1st gen....funny how a 'compact' SUV these days is dimensionally close to the fullsizes of yesteryear.

Good drivetrain combo. It's gotta be costing some bux in shop time. Glad I was able to fab mine up on our own.

A SAS truck with the 2nd gen power does sound good. Too bad about the heater knob 4wd and lack of crawler gears though.