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Old December 3rd, 2009, 07:07 PM   #1
08rangerdan
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Default 08' ranger SAS build up

hey everyone im just getting ready to begin one of my most interesting projects, so im going to start posting here for all my progress as it starts falling together. ill also be asking any questions and ill also be looking for feedback on anything ill be posting.

ill be working on my fairly new 08' ranger sport 2wd w/ auto 3.0L...

my first stage of my ranger was honestly not intended to lead me to all the hassle im about to get into. ive currently got my ranger set up with fabtech spindles, aal, and clear a 32"x11.5 tire with no trimming on a 15x8 wheel. it just isnt enough of a truck for me.. with one winter down on the truck, in this set up proved i needed to do more to keep me driving and keep me from getting stuck. i also want to be able to do some moderate offroad and tackle some trails in and out of my area. and in the end it still needs to be my daily driver and be as reliable as i can get it.

i plan to build this up in 3 stages and my first area of construction will be to get a functional driveline, and eventually install it. ive been having an incredibely hard time trying to find a B/W1354m within my border so i needed to look else where. i finially found a 1997 ford ranger B/W1354m in a scrap yard in some far off state. tomorrow ill be getting it shipped to me for sometime next week. once i get it ill be tearing it apart and hopefully be happy with what i see. the case itself has no linkages or anything with it so i will need to find a linkage and lever that will work with my 5R44E auto trans, floor plate, boot and bezel, and of course and extension housing and output shaft. if anyone can help, please inform me, if not ill be purchasing new parts from ford.

ill keep you posted,
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Old December 15th, 2009, 05:57 PM   #2
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my 1354 manual came in today, it was lost in shipping for a little while. overall im impressed with the condition. it came out of a 1996 mazda and has just about 200000 miles on it, as im told. got it at lunch this afternoon and cleaned up the outside a bit and when i got home i tore into it to see what damage was done in 200000 miles. but every thing looks to be in sound shape.

i only noticed very minor chipping on the planetary set but im sure its nothing to worry about, ill show a picture to show what im talking about, you will notice a pattern of 2 chips per tooth where something got ground in there at some time in its last life..
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Old December 15th, 2009, 06:01 PM   #3
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more pics of the tear down, next ill just be cleaning it up and stripping the last few sections of the housings for clean up
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Old December 15th, 2009, 06:07 PM   #4
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Cool looking project. I plan on doing this to my ranger as soon I get some extra cash.

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Old December 15th, 2009, 06:07 PM   #5
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im not overly sure what to replace because most of the parts looks fine, the ball bearings on the outputs feel a little run out but no slop and the roller bearing inside the planetary feels slightly gritty but usable.

>should i just go for a basic seal replacement or go with a full bearing replacement also?

>does anyone know how to release the planetary set from the transfercase back plate?

>is there anything else i should take a close look at?, as this is a first time at driveline repair for me, so i dont know exactly what to look for
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Old December 15th, 2009, 06:12 PM   #6
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sounds like the start of a fun project and one that i'll be following. i've been thinking of building a Ranger for my next project. what are your plans for suspension?
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Old December 15th, 2009, 06:23 PM   #7
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the goal is a drivable trail capable truck with little intension to go big as of now. possibly a future project may expand this trucks capabilities more but for now its still my DD

front:

leafed
dana 44/(waggy, f150)
electronic locker
5.13

just the basics im kinda going with this as i go and what i find, but those are the crudencials im starting with to get my mind going

rear:
8.8
possibly just a skyjacker FR36 spring but preferrably a longer chevy spring
electronic locker
5.13

looking to get a 37" tire on it and still be ok on the freeway also

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Old December 16th, 2009, 10:58 AM   #8
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i'm looking forward to more
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Old December 16th, 2009, 08:32 PM   #9
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make shift wash bin, and removing old sealents. mineral spirits and gasket remover are good things, just dont breath to deep..
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Old December 16th, 2009, 08:33 PM   #10
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my vac. switch on my case is broken but im just wondering since im 2wd do i use the vac. switch on my t case? what does it do? does it just activate the 4x4 lights im assuming? and where is a good place to run a line from the vent nipple? just inside the firewall someplace? im very likely just to close up the vac. because i dont see it playing any importance in the function of the case in my truck
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Old December 16th, 2009, 08:34 PM   #11
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ive pulled a bearing from one of the outputs and im pretty sure its usable but its not ideal. i want to get alot of milage out of this vehicle so im going to replace all of the bearings and seals and call it complete. maybe $100 to complete the rebuild when i order the parts, ill find out tomorrow. ill also use all new hardware and plug that vac switch in time..

prep for sandblasting the case halves,

i find using vinal electrical tape makes really good masking tape to pick out good lines and sticks quite well, i filled big areas with simple spread paper used normally for covering a doctors bench, but works well.
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Old December 16th, 2009, 08:35 PM   #12
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good progress today but i made a few mistakes,

the sandblaster was acting up today but i managed to get the first half of the case restored as new, and also hit the rear drivshaft output and cleaned that up. i also dipped the output in black oxide, looks pretty nice now.

i also managed to get the snap ring to release the planetary. i was trying to seperate the prongs but i actually needed to compress the spring clip instead because it rests inside of a lip not on the outside, duhhh lol. i just couldnt picture how it was together last night but now i got it..

now for my mistake of the week,
as i was finially removing the bearing off of the planetary set. i engaged my bearing puller and began wrenching on it, and as i did, i noticed my placement of my tool was far from ideal. i had put the threaded center from the tool down into the input spline and right ontop of a thin case of the needle/roller bearing for the main shaft. i didnt realize what my tool was putting its leverage on. but by the time i realized what i had done i already had a nice hole poking through the bearing case lol. replaceable but quite dumb of me. i then persisted my bearing removal by using a block on top of the input to put my leverage on and ting, ting ting, pop! it was off..

to fix the damage i removed the center shaft of the planetary and quite easily knocked through the holy bearing and the brass bushing, which i will also replace now, since i have it out..

now to progress my teardown i will need to find, or modify a socket that clears the front drive flange pocket to remove the nut on the front shaft. the clearance is to tight to get an ordinary socket in there. for now all my cleaned and restored parts are organised and stored awaiting the next step,, assembly..
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Old December 16th, 2009, 08:50 PM   #13
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Check the chain for slop, you can buy a new chain at NAPA. Also check the oil pimp filter screen assembly for any damage and the hose itself for any cracks or splits. The 1354M is a damn strong case. Ran one for years in my truck from 33's to 40's and as well as a doubler.
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Old December 16th, 2009, 09:33 PM   #14
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thanks,

the chain and alot of the other components are in very mint condition, so im very confident about these components lasting for a while.

the only thing i noticed about the the pump assembly is that the casing has slightly worn down and has chaffed/cut into the case a bit excessivly. the pump while on the shaft will actually rub the wall of the case with its edge. im assuming stop and go is the culpret of the chafing of the case and the pump but its still in good shape mechanically and i dont know if its worth replacing it. here is a picture of the damage to the pump and the case where it rubbed itself down. i planned on removing the burr from the pump and replacing it back into service.

if it will likely become a problem let me know and ill add it to my replacement list but im trying to salvage as much as i can
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Old December 16th, 2009, 09:35 PM   #15
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i might just weld up the missing porting of the pump also and file it back to a recognisable design, i dont know how much is actually missing of it because i have nothing to compare with.
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Old December 16th, 2009, 09:40 PM   #16
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The pump sits on the shaft, but If I recall right the pump body itself doesn't move. Its suppose to sit against the case and hold its position. Your pic of the pump looks like it has a broken ear....maybe where it holds against the housing?

Also, that "vacuum switch" isn't a vacuum switch or at least on the older model 1354's it isn't. It was a 2 wire switch to turn on the 4x4 light on the dash.
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Old December 16th, 2009, 09:57 PM   #17
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not sure if it helps but

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Old December 16th, 2009, 10:01 PM   #18
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Quote:
Originally Posted by CheapThrillB2 View Post
Also check the oil pimp filter screen assembly for any damage...
I wish I had an oil pimp, imagine all the chics you will get

subscribed, this is going to be a cool build to watch-- keep us posted
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Old December 16th, 2009, 10:02 PM   #19
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Old December 16th, 2009, 10:03 PM   #20
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ok i see, the pump itself just sorta floats on the shaft and slightly moves with the shaft when it starts moving, overtime im assuming it just beat itself up knocking itself into the case. i can just fix up what i got and make it work again good as new, and for that switch, ill just plug it up, do you have any clue what that thread is? 16mm?
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