Dana 44 Crossover steering (Updated Finally)

[NV_K5]

Ok so this thread is almost a build thread because as most of you know things snowball when working on 37 year old trucks.
So a few weeks ago I pulled the Jimmy into the garage to install the twin stick kit I bought and replace the bushings – http://coloradok5.com/forums/showthread.php?t=246762 all went well and the twin stick option is nice but a lot of work and as yet to pay off.

Then we go bounce and try it out. While bouncing the rear end is still very mushy and gives a lot of body roll when I have the top on. Some may recall I have been dissatisfied with my rear shackle flip and spring combo so I decided to firm up my rear end with new 5/8” U-Bolts and Superlift HD Overload/Add-a-leafs, new shocks on order. Also as you can see the 4 degree shims aren’t holding up either so for now (very short) I will have to leave those out.
Not a very good picture of the overloads but trust me the springs looks a lot firmer now.

Summit part no. SJA-R225 and U-bolts part no. SLF-11334.

You cannot really tell from this below picture but the shims are wasted.

At the same time I bought new Ball Joints and a Rag Joint from Summit for the front end just in case I got motivated and while it was already in the garage – which is a pain because with the top on, I have to remove all four wheels and install a set of steel rims with no tires to clear the garage door. Maybe I need to just scrap the top and most of my problems are solved. Hummm?
Ball Joint(S) Summit part numbers MOG-K8194T and MOG-K8195T

So no **** there I was looking at the front left upper ball joint which isn’t holding up to its end of the deal when I realize Taxes are done and should be hitting the bank account any time now. Well that got both the brain cells firing and I did a search (again) for right flattop knuckles. Enter Chickenrammit with what I thought he’d already sold. We’ll skip the details of that since it doesn’t take long for a user name like Chickenrammit to get out of hand – see what I mean? Anyway bought his flattop knuckles.
Before:

I thought flat top knuckles and new ball joints in addition to the other stuff already mentioned would surely be the end of my fun and my wife would “intervene” in my addiction for spending money but no – she suggests I just get her done! I thought I’d have to sell a kidney or something to buy the necessary parts to finish off my crossover steering.

So I continue on my ride to ruin and call Trevor from WFO Concepts and price their crossover steering kit which includes new pitman arm, 1.25x.219 dom draglink, two rod ends w/nuts, and one Tall steering arm and hardware (studs etc.) Trevor hooked me up since I’m a returning customer or something he gives me the deal of the week; not full retail.

After these are installed I’ll call Trevor back and give him the dimensions and included in the above price is a custom drag link. (Not shown)

New 2wd steering box from Napa Part no. NSP88278052 and Summit Rag joint Part no. BRG-000941

Knowing how hot the power steering fluid got on the Rubicon, and knowing a bag of kitty litter is already in my future I also bought a Permacool power steering cooler kit from Summit part no. PRM-1007.

Ran out of hose last night – story of my life.

 

[Greg72]

Pretty GREAT story so far if you ask me....

There's something to be said for being able to do some mods, and then get back out and actually DRIVE your 1st Gen again to enjoy it. I'm definitely jealous about that.

 

[NV_K5]

Thanks dude I appreciate the positive feedback. Like I said earlier the thing snowballs so who knows when I'll actually pull her out and abuse her.

 

[Blazin'4x4]

While your in the mood to replace ball joints, I highly recommend the knuck joints, or else.....

 

[NV_K5]

That thing had to show signs of road rash or something prior to crapping it self? right? Did you replace it with Knuckle Joints? What are they? Any photos?

Regardless, tonight I have a hot date - with my K5 putting all this stuff together and getting the length for the drag link. Oh and drinking beer, cannot forget to lube the pipes.

 

[Blazin'4x4]

The ball joints that attach the knuckle to the axle broke in half. Dont think they were made for 39.5 super swampers.

 

[NV_K5]

I finished the installation of the steering box and cooler with no real issues.

I couldn't get the drivers side knuckle off the axle so the usual recipe of BFH, heat, BHF repeat finally did the trick.

The passanger side was another story, I ended up cutting the top ball joint stub and drilling - not pretty. I decided to replace the ball joints in the right knuckle because I just didn't want to do this again real soon. And while walking around my truck (probably looking for my beer) I put the "New" insert from the set installed in the knuckles upper ball joint around my finger and it snapped in half, not my finger, the insert.

By this time it's really late and borrowing tools it now out of the question, so I replace ball joints using hand tools, old sockets, pipe and a bench vise. I broke two drill bits on the knuckle removal, a file, a hammer handle and my bench vise - no really it's broken in the middle. I have an old press in my back yard but it's covered with other parts and tools etc. I sneak it into the garage around 3:00 AM and finally get the new ball joints pressed into the knuckle.

Then I cannot get the new insert to seat and the Snap-on socket isn't quite long enough. So it's installed with a cold chisel and a framming hammer.

I painted the arm and installed the studs, took a measurement and went to bed - 4:00am.

Today WFO sent me the drag link so tonight I'll install, bleed the PS and take some more photo's. Until then here's the newest:

 

[Greg72]

Tenacious!

Keep it going

 

[bp71k5]

I may be wrong, but is your steering arm missing the cone washers under the nuts or are they just really small?

 

[NV_K5]

No the arm is really thick.

 

[bp71k5]

The holes in the arms look so small that I didn't think those huge cone washers could fit inside those. Is the arm extra thick to let the draglink clear some blocks\shims under the springs?

 

[NV_K5]

The photo is deceiving, the arm is huge for just the reason you asked, I have 5 springs and angled shims. I bought new conical washers, studs and nuts as part of the kit from WFO. I didn't want to reuse the old ones. The holes are also countersunk so if for some reason you needed to add a spacer uder the arm you could without changing the studs.

 

[bigbadchev84]

Looks good Joe, And your old pitman arm works awesome on my truck! I just want to let everyone know what a great guy Joe is, I pmed him about his old dropped pitman arm and he sent it right out before receiving this is why I love CK5 so much.

 

[ChickenRammit]

hey joe, i'm glad to see that you put those knuckles to good use. looks like your crossover project is going real nice.

 

[NV_K5]

Looks good Joe, And your old pitman arm works awesome on my truck! I just want to let everyone know what a great guy Joe is, I pmed him about his old dropped pitman arm and he sent it right out before receiving this is why I love CK5 so much.

Thanks for the kind words!

Sorry I haven't been able to get online lately - this actually working thing is a drag.

Here's the truck as she sits today, I lightly bounced her last weekend and the steering is a TON better than it was before: turns sharper, smoother and believe it or not it doesn't crackle and pop while turning anymore. I need to re-tighten and tape measure align, but mostly this phase is done.

I cannot tell you too often that if you need to upgrade your steering etc - Trevor at WFO concepts is the place to call.