Project MULE - Expedition build on a 1991 1500 4x4 Suburban

[PMA4x4]

XJ Steering shaft mod done. This is the shaft from a 84-94 Jeep Cherokee. I had to put a small cross notch on the column side to allow room for the cross bolt. Other then that it slipped on perfect.

The gearbox side has a flat side the will mate up with the shaft. so just make sure your pitman arm is centered and the steering wheel will be centered.

I have seen some make stop nuts and other ideas for keep the telescoping shaft rotate within in each other to keep tight steering. I am leaving mine loose and will see how it feels. This needs to be allowed to slide in and out in case of a accident so you hopefully don't get the steering wheel jammed into your chest.

 

[PMA4x4]

Stock spring hangers on the left and Off Road Design's on the right. The upper bushings on the stock ones felt like plastic. Not hardened rubber or bad rubber but actual plastic and i could see what appeared to be a mold seam line in them. Uh, yeah....no.

ORDs are polyurethane and fully greasable. The plates are also much thicker for added strength.

Taking the new front springs apart and getting them greased up. I use a white lithium grease. This will help from any possible squeaks and will keep the suspension moving smoothly.

Finally getting the new axle in. It was a bit slow being just me but with the floor jack and a cherry picker it made life easier.

Old height

New height +5.5"! Granted, it has not settled nor does it have the 200lbs of winch and bumper on it. and I am pretty sure my stock springs were THAT SHOT!

 

[PMA4x4]

with having a small lift (compared to most) I felt I did not need the extra long extanded stainless steel brake hoses offered forlifted trucks and frankly i didnt want to pay that price either. after searching the forums for a bit I came across a couple options and what seem to be the best was this one.

THe stock brake hose for the front calipers is 19" long. the new one I chose is 25" long, a nice additional length. The Hose I am using is for a 1991 Chevy C3500 with a 5.7 and is a Napa #38872 and was $13.49 each. There was nothing showing this line to be left or right so I ordered two of them. They fit perfectly. The suspension is sitting on jack stands on the axle so its sitting a rough idea of a ride height.

I am sure you have come across this brake hose in your searches but I thought I would add some pics to the info.

 

[WhiteEvo]

Larry,
What front springs did you use?

 

[Larry]

My burb has an old set of 4" Rancho springs that came off my K10. The K10 has a set of Superlift 6" soft rides. Both also have a set of the ORD HD front shackles like PMA used.

Larry,
What front springs did you use?

 

[WhiteEvo]

Whoops, that question was for PMA4x4, hahaha, I'm confused now!

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[Larry]

Whoops, that question was for PMA4x4, hahaha, I'm confused now!


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I was wondering about that. Lol

 

[PMA4x4]

Larry,
What front springs did you use?

Haha, I'm PMA4x4 that's larry and this is the mousketeer club!

Evo, I went with the Tuff Country 3" HD springs. It pretty much same price as the regualr 3" springs but you get that little short leaf to ad a bit more spring load. If it rides too stiff or too high you can always take that little one out. I am leaving it in for now to see what happens.

 

[WhiteEvo]

Thanks Guys! Been a LONG week! 😊

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[Renntag]

Stock spring hangers on the left and Off Road Design's on the right. The upper bushings on the stock ones felt like plastic. Not hardened rubber or bad rubber but actual plastic and i could see what appeared to be a mold seam line in them. Uh, yeah....nRDs are polyurethane and fully greasable. The plates are also much thicker for added strength.

The ORD hangars look great. Not sure what they cost. I am looking to beef up the suspension, brakes, and axle. I like what you have done.

Taking the new front springs apart and getting them greased up. I use a white lithium grease. This will help from any possible squeaks and will keep the suspension moving smoothly.

Looks great. If you mentioned what springs you chose, I must have missed it. Curious what you decided to go with and the rough cost. Nice that you went so far as to take the new springs apart and proactively address noise issues.

Finally getting the new axle in. It was a bit slow being just me but with the floor jack and a cherry picker it made life easier.


New height +5.5"! Granted, it has not settled nor does it have the 200lbs of winch and bumper on it. and I am pretty sure my stock springs were THAT SHOT!

Keep us updated. Looking forward to feedback as to ride improvement on and off road.

 

[PMA4x4]

This is the most un-natural act I have ever done. It feels SO wrong.:screwy:

 

[PMA4x4]

Renntag, ORD has everything you are looking for. I went with 3" HD Tuff Country springs. 3 years ago when I got my OME springs for my Cherokee from Will at Sierra Expeditions had mentioned the greasing. I did that and it s now a normal thing for me.

I still have to do the rear axle so maybe this weekend..

 

[Renntag]

Thanks for the info. I'll check in with ORD and see what my options are. I plan to repower with a cummins and will need to address front suspension capacity and axle strength. Hence my question.
I may tough it out with the stock axles for now and continue to search for a reasonably priced swap solution.

Thanks for the info.

Internet was down earlier and I noticed this message never updated. Here goes: (after you posted the Jeep steering shaft mod).

Nice mod. Looks like you started with a brand new shaft assembly? Where and how much?
Each update keeps this in the territory of "Epic build".

 

[piratexpress1369a]

This is the most un-natural act I have ever done. It feels SO wrong.:screwy:

that looks so funny with those small wheels ..stay on it the end is near

 

[Renntag]

Just occurred to me that with the baby tires (235 ?) you are ready for air bags and cruising the BLVD in Long Beach.