04 Dakota SAS (Updates)

Some of members expressed interest when a Durango project on 42's was present in a couple of my Waggy build pics. That project is still not finished, but last week we completed a Dakota on 37's. The owner is from Lab city NFLD, he drove the 1168 KM here to Freddy and will drive it back, we have just 7 days to complete the transformation. Specs are 9.25" rear with a Detroit, front HP D44 w/ ARB both 4.56. T- case is basically a electric shifted 231, so all that was necessary was to install a CV style 1310 yoke and build a new FT DS
The victim, came in with 3" body list and a leveling kit




First step was to install a steering box as the Dakota was rack and pinion, this was as low as I could place it as the motor mount was in the way, and would have involved too much work to get around or relocate. Mounted it as far forward as I could. I was lucky and the stock PS lines bolted right up.







Did a simple shackle flip in the rear as I only needed 4" of lift







Moving on to lower control arm mounts





And upper link
Nice to have new clean brackets to work with



7" of separation



Now get it off the lift and on the ground for the removal of the IFS and mock up of suspension.

Bye Bye IFS


frame prepped






Filled in



Joints and stuff


suspension mocked up





9" of separation at Ft links




Final Axel prep and welding


Suitable cover



Checking full stuff







Full droop, Drag link 36" track bar 34.5"









And some completed pics










My last task was to install the rear gears, sorry no pics, upon removal of the gears I discovered the stock factory trash lock, clutch keeper clips had worked out and cut a 1/4" groove all the way around the right side cap and bolt boss. I informed the customer and we install the gears and locker, it was a risk, but customers call.
Put it on the ground did the measuring tape alignment. I did the road test for initial gear break in, handles great no quirks. It was 1am on Friday so no time for ramp tests or tweaks. He rolled out at 6am. The project took roughly 100 hrs to complete, we charged him 75 hours. I'd like to thank my co worker John who is the best template maker ever and knows how to use a grinder.
He was a great customer, came in daily to check updates, but never got in the way, and was very happy when he left. I'll update if there is any problems or changes.