Solid axle swap: yay or nay?

[Roadranger]

So I'm running a '13 Sierra half ton as my primary adventure vehicle. It's reasonably capable with 32s, a factory lift, an E-locker in the rear and rancho shocks and struts of some designation I can't remember. It pretty much goes everywhere I want it to, and I'm typically more interested in the destination than the off roading. However, I like the insurance of added capability just in case, and in theory a solid axle swap should make it much more durable and reliable. So, do the pros outweigh the cons?

 

[Dalko43]

There is thread somewhere on here about someone who did a solid axle swap for a Silverado 2500 (i think it was also posted over on pirate 4x4 or something similar). I forgot the poster's name, but his build had a lot of attention to detail (3d plans, fabricated the new suspension mounts, may have even done something to take of ABS issues). From how the report read, the build turned out pretty well and the vehicle seems to handle nicely.

My honest opinion is that buying a vehicle that already has a front solid axle (or simply reinforcing your existing vehicle IFS) is an easier and less expensive approach. But if you really want to do a SFA swap, it has been done with other vehicles....you just have to figure out if it's worth the time and cost.

 

[Roadranger]

Thanks, I'll take a look. I would agree with you were it not for the immense sentimental value of this truck.

 

[Buliwyf]

I'd beef the rear axle. Get some flares and go up to 33" MT's.

A SAS can cost as much as an entire beater F350 with solid axles. Unless you're going to hardcore 36"+ tires, a SAS might be overkill.

 

[krazytoy]

You need to ask yourself, deep down, is it a "want" or "need". It's an expensive endeavor with trade offs, you will want to be sure that you understand all of those trade offs and are willing to accept them before you make up your mind.

 

[Roadranger]

Definitely a want. 33s are about as big as I want to go. I'm basically interested for the increased durability, but I'm unsure if that would be worth it.

 

[mccustomize]

Quality mid travel kit with upgrade steering and you'll be fine.

 

[TCICapn]

Sage words from krazytoy for sure. If you don't want to do technical offroading/rock crawling I'd vote for leveling out the truck on 33s and call it good. That's about all I've done to mine and it's taken me places I thought I had no business going without a problem so far (knock on wood).

What I would also recommend is sliders and skids as they have paid for themselves many times over and I've only had them for about 6 months. Unfortunately for us that generally means custom. If you're interested I can post up who I got my generic sliders kit from.

 

[superbuickguy]

The question is always - how, when, where, what. IFS is far more liveable on the street, sometimes rocks and running open desert. Solid axle is far better in mud, snow, and sometimes rocks. So when you ask "what should I do" the same question is asked of you. What do you do? IFS is more expensive to make bulletproof, however, when it comes to long distances and or long distances over rough roads - I'll take IFS over solid axle every time.

As for durability, I think you forgot about the human element. I have an 1985 Suburban and a 2004 Denali - when I need to get to California and will be driving long distances.... I'll take the Denali every single time. It's so much more comfortable and comfort equals safe driving. That said, if time isn't really an issue but vacation is.... I like the trips and the often stops to see what's around me - so I don't care so much about solid axles riding harsher or following the ruts in the road.

Notice something, though, I haven't mentioned durability. The Denali has 183,000 miles, the Suburban 300,000 miles, my H3 has 150,000 miles (and I've had countless other 4x4s)... cost over the long haul is about the same. The only part of the Denali that has been replaced in 183,000 miles is the idler arm (about 30 bucks). The Suburban has all brand new bushings and new springs - on top of that, I had to reweld the frame where the shock mounted. I don't think those fixes were really atypical for the breed (I've owned a bunch).... My H3 - had a steering rack replaced at 80,000 miles but otherwise has its factory stuff still on it. With that said, I wheeled it pretty hard and ended up replacing a t-case and having to rebuild the front axle. While that could be kind of damning for IFS, I don't think, given the how-it-happened, that I wouldn't have been doing exactly the same repairs if it were a solid, dana 44 front axle...

now my advice from your limited post - stick with the IFS, your back, wife, and wallet will love it. If you really feel the need to drop $5,000 on a front axle then another $5,000 having it installed - spend the 10k on a side-by-side.

 

[Roadranger]

I would definitely be interested in seeing where you got your sliders and skids. Thanks everyone, I think I'm convinced to leave the truck IFS. For quite some time at least.

 

[TCICapn]

The sliders are a generic kit from Chassis Unlimited. I think mine are the 96" variety (longest available) to cover wheel well to wheel well. I had a local welding shop weld them together and then to the frame since trying to go bolt-on was a nightmare and a half. They've been great so far, they can hold up the weight of the truck but do flex pretty good.

The skids I found were from a one-man outfit back east but he only made the one set and they are only 4mm thick aluminum, do I wouldn't really recommend it. I know they won't hold the weight of the truck but I have bellied over some sand and dirt mounds with them. I will likely use them for a template for some beefier 3/16" steel skids down the road. I still need to start a build thread to record all this stuff, then I could put up measurements for the skids.

 

[chilliwak]

The big question is how much fabrication can you do yourself? If you have time to get the parts when they are on sale cheap then I think you could do a sas with a Dana 60 for less than $2000. Like the other posters have mentioned you have to ask yourself whether a sas is for you. I personally like what others would call a rough ride in that the vehicle then tells me about the terrain I am crossing by giving me a kick in the back. For offroad a sas is king. I hope this helps. Cheers, Chilli...

 

[Buliwyf]

If the truck has sentimental value? Why hack it up?

There is some risk involved. At best it'll be as good as an olde solid axle 80's truck. It won't have a refined ride like a newer Dodge or Ford. You might actually make the truck worse. (...and I'm an IFS hater) I'd just fix it up a little more, use the highest quality components and you won't need giant lifts or an SAS.

A buddy of mine loved his old Dodge. But it's axles were toast, frame was bent and rotted out, it's suspension was obsolete garbage. But it was the only rust free old Dodge on the east coast. He pulled the body, engine and transmission, and transfer case. And dropped it on a 2001 Ford Superduty chassis (scrap yard roll over victim). Truck was never the same, even though it was better in every sinfgle way. A really cool truck, but different in every way. Because it was so good, much of it's sentimental value disappeared.

A Jeep Wrangler is another perfect example. A mildly built Wrangler is a ton of fun. Just enough capability, without making things too easy. But a well built Wrangler is boring as heck. Nothing's a challenge for them, and they're worse on the road. Sometimes even to the point that you can't travel with them anymore. Off roading becomes boring, easy, and unrewarding. And a PITA because of the quirkiness of a well built Wrangler. Then you go all in, and start towing it to the trailhead with a truck and flatbed trailer. Which is even less fun and a ton of $$$. BTDT, I may never own a Jeep ever again.

The flip side of the coin is, if the trucks is of sentimental value because of it's mileage and travels, and every single dent tells a cool story, and every single body panel is dented, then go for it. SAS a beater thruck is great fun. But if the truck is sentimental, and in good condition like a Mustang where you don't want to risk dinging it up, it ain't ever going to get wheeled hard enough to need the SAS anyways.

 

[Dalko43]

If the truck has sentimental value? Why hack it up?

There is some risk involved. At best it'll be as good as an olde solid axle 80's truck. It won't have a refined ride like a newer Dodge or Ford.

I think that last point hit the nail on the head. Doing a SAS swap on an older 4x4 or truck might work out okay, because chances are the ride and street comfort were never really all that great anyways (at least by today's standards). But putting a SAS on a newer truck, it will be hard to replicate the capability and refinement that you could otherwise get if you were to just go buy a modern vehicle that has a Solid Front Axle to begin with (or a well-designed IFS).

And that's not knocking the people who have done SAS swaps on newer vehicles like Silverado 2500's, because I'm sure there are people out there who have the time, money, and skill to work through such a project. For the average DIY-minded offroader, I just don't know if the juice is worth the squeeze. Personally, I would find it difficult to spend all that time and money, and assume the potential risk, doing that kind of modification when I could just go buy a well-designed, and warrantied, vehicle that already has that kind of suspension set up. That's my view anyways.

OP, if you do some searching around here and talk to some of the members, you'll find more than a few Silverado HD owners who have made some upgrades to their IFS setups and have done just fine traveling and wheeling around. As long as you drive appropriately, I don't think your IFS will limit you in your travels.

 

[ExplorerTom]

You might actually make the truck worse

I SAS'd my Explorer. ^This^ has crossed my mind more than once. The increased trail capability is great. It'll go just about anywhere now. I don't think I've lifted a tire since the SAS.

But mine is pretty finicky. It seems like I'm constantly replacing something. And the on-road manners aren't the best. They actually suck- turning radius isn't very good, springs are soft so there's some roll.

Would I go back? Well, I can't- without just as much work as the SAS to put the factory stuff back. But no, I wouldn't go back. It's a great offroad rig.