Project Merc...

[Stang5lgt]

I am going to start a build thread for my 98 Mercury Mountaineer SAS. It has been on the road since Feb I bought it wrecked in Jan. I got a new toy for it today. 3 speed STaK Mini Monster 5.22, 2.97 low ranges. I can't wait to get it in and try it out.;)

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0338.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0339.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0340.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0341.jpg
Next to the 4406 what I have currently in the Merc.
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0342.jpg

[mattzj98]

Good job now put it on and come wheeling with me!

[Popsgarage]

How much did that B E A U tiful chunk of SEXY machined aluminum set you back. I mean, damn that thing is GORGEOUS. :thumb::cool::cool::thumb::cool:

[Stang5lgt]

Good job now put it on and come wheeling with me!
LOL I should have it in next week and then I will be ready to go wheel with you. :D

How much did that B E A U tiful chunk of SEXY machined aluminum set you back. I mean, damn that thing is GORGEOUS. :thumb::cool::cool::thumb::cool:
$2,685 to my door. Not bad considering a Atlas 2 speed would have set me back around $2,400 shipped. And yes I sat there and stared at it for an hour after I got it. While I was staring people were talking to me I can't remember a thing they said(I am thinking to myself can't you see I am having a moment here). :D I asked my wife if it could sleep in the bed with us. LOL She laughed at me.

[Brad]

Stunning piece of machinery you have there. I would have a moment too. :thumb:

[jesse05lj]

Very nice!!!

[Popsgarage]

I don't know if I'd want anyone to see my moment. :D:D:D

[Fordguy77]

Very Nice!

[Colin]

Looks fricking sweet!!!!!!!

[Zukrider]

whats it replacing? 231?

[Stang5lgt]

Replacing a BW4406 F150 transfer case. It has 5.22 and 2.97 low ranges.

[Stang5lgt]

Reason I decided to upgrade was I took a day off work and couple friends did too. We were going to run Holy Cross well half way up the first shelf road my transfer case shift fork bent or something and the case started shifting on it's own. So I had no 4 wheel drive. I had to turn back and my friends didn't want to leave me so they followed me down. I didn't want to be let down like that again so I ordered the STaK.

Here are some Merc pics.
http://i24.photobucket.com/albums/c16/Stang5lgt/00164_Capture_1.jpg
http://i24.photobucket.com/albums/c16/Stang5lgt/IMG_0266.jpg
http://i24.photobucket.com/albums/c16/Stang5lgt/IMG_0283.jpg
http://i24.photobucket.com/albums/c16/Stang5lgt/00149_Capture_1.jpg
http://i24.photobucket.com/albums/c16/Stang5lgt/00138_Capture_3.jpg
It flexes ok for a Ford. ;)
http://i24.photobucket.com/albums/c16/Stang5lgt/710.jpg
My trussed Dana 30 with 4.88 gears, Truetrac, Heim/DOM steering, Hydro assist, Solid diff cover, and still rocking stock shafts! LOL
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0112.jpg
I wanted to prove to some of the Ford guys the Dana 30 was tougher then they thought. So far been to Moab, Chinaman Gulch, Eagle Rock, Kelly Flatts, Wheeler Lake, and few others. And I daily drive it to work. Put about 12k miles on the SAS setup so far. Nothing has broke. And to the axle already had 170,000+ on it before I got it. :D

[TNT]

Soooo jealous! Looks way better in person! :bowdown:

[jesse05lj]

probably the most bad ass Mercury I have ever seen!!! very noce job! you don't see to many of them on the road.

[Popsgarage]

I wanted to prove to some of the Ford guys the Dana 30 was tougher then they thought

Gonna use one in the wife's S-10 Blazer one of these days. Nothing wrong with them if you are just careful, easy on the skinny pedal, and build them with decent parts.

[Stang5lgt]

Gonna use one in the wife's S-10 Blazer one of these days. Nothing wrong with them if you are just careful, easy on the skinny pedal, and build them with decent parts.

Should be doing the same S10 swap next month. Brother in law is bringing his Blazer out so I can help him with it.

[jesse05lj]

ya not a bad axel the only real downfall is the ring and pinion size.

[Fordguy77]

I wanted to prove to some of the Ford guys the Dana 30 was tougher then they thought. So far been to Moab, Chinaman Gulch, Eagle Rock, Kelly Flatts, Wheeler Lake, and few others. And I daily drive it to work. Put about 12k miles on the SAS setup so far. Nothing has broke. And to the axle already had 170,000+ on it before I got it.
Its not so much as i think the Dana 30 is weak, its more that i can get "heavier stronger" axles for the same as a Dana 30, so that's why i wouldn't run it personally. However it is very cool to see you wheeling it with so much success! I like the merc! This was pretty much the direction i was going with a 88 B2 that we ended up selling before i finished it.

[Stang5lgt]

Its not so much as i think the Dana 30 is weak, its more that i can get "heavier stronger" axles for the same as a Dana 30, so that's why i wouldn't run it personally. However it is very cool to see you wheeling it with so much success! I like the merc! This was pretty much the direction i was going with a 88 B2 that we ended up selling before i finished it.
You may be able to get a Dana 44 for the same money. But then you have to narrow if you don't wanna run full width. You have to buy brackets the Jeep brackets for the set I am running cost 500 bucks. Then you have problem of different bolt pattern. Then the gears and lockers and rest of the parts cost more then Dana 30 parts. With the gears, Truetrac, and buying the axle I have $530 in it(only paid $40 bucks for the axle). The truss I used some scrap metal I had laying around. Now if I built a Dana 44 I would have $1200+ in it just to get it where my Dana 30 is now. Then I would have to get adapter spacers for the rear to get the bolt pattern from 5x4.5 to 5x.5.5 like a full size Ford(Dana 30 is already the same bolt pattern and even uses the same lug nuts). Not to mention the hours of work to get it set up. And the only real gain would be I get bigger ring and pinion and be able to go lower then 4.88. The Dana 30 uses the same U joint size as the D44. Guys on Explorerforum told me I wouldn't make it one trail with a D30.:rolleyes: LOL Plus if I decide to build a bigger axle later I can sell the Dana 30 to a Jeep guy since I left it pretty much stock. I can buy a lot of stock shafts for the money I saved still rocking the factory ones with over 180k (Jeep had 170k the axle came out of put 12k on the axle since) on them and over 10 trails.

[Fordguy77]

You may be able to get a Dana 44 for the same money. But then you have to narrow if you don't wanna run full width. You have to buy brackets the Jeep brackets for the set I am running cost 500 bucks. Then you have problem of different bolt pattern. Then the gears and lockers and rest of the parts cost more then Dana 30 parts. With the gears, Truetrac, and buying the axle I have $530 in it. The truss I used some scrap metal I had laying around. Now if I built a Dana 44 I would have $1200 in it just to get it where my Dana 30 is now. Then I would have to put adapter spacers for the rear to get the bolt pattern from 5x4.5 to 5x.5.5 like a full size Ford. Not mention the hours of work to get it set up. And the only real gain would be I get bigger ring and pinion and be able to go lower then 4.88. The Dana 30 uses the same U joint size as the D44. Guys on Explorerforum told me I wouldn't make it one trail with D30. LOL Plus if I decide to build a bigger axle later I can sell the Dana 30 to a Jeep guy since I left it pretty much stock.

Very good points. I've never converted anything to an Solid Axle, to be honest I don't even mes with ford ifs, just TTBs. And if I was going to do this converison I seem to over look most of this as I have more than a few narrow 44s laying around with matching 9s. I've collected far to many early bronco parts over the last few years. Its not the ujoints id be worried about, more the shaft strength... just my .02s though. I'm more of an early RBV guy myself and am a big fan of cut and turned 35s. Still great rig and awesome work!

Sent from my T-Mobile myTouch 3G Slide using Tapatalk

[Stang5lgt]

Well on the newer Mercury's and Explorers the speedo runs off the rear axle abs sensor so I needed to stick with stock or another axle that came with a ABS sensor. I thought about the early bronco axles but they are too narrow for what I wanted to do. My original plan was late 70's F150 D44 high pinion narrow it to Wagoneer 44 width which is 63 inches so I could use Waggy shafts. Then I was going to run 1.5" spacers on the rear to get the 8.8 from 59.75" to almost 63". But to speed my build I just built the D30 figured if it broke I could always build another or build 44. So far so good.

[Popsgarage]

Should be doing the same S10 swap next month. Brother in law is bringing his Blazer out so I can help him with it.

Shoot me a PM when you do this. I've never done one, so I'd like to come help. That way I have an idea of what I'm getting into.

[Stang5lgt]

Shoot me a PM when you do this. I've never done one, so I'd like to come help. That way I have an idea of what I'm getting into.

I will find out when he is coming out and let you know. I will be in my new shop by then a lot more room to work.

[Popsgarage]

What kind of conversion are you doing on his?

[Stang5lgt]

Dana 30 swap similar to the Merc and TNT. I just talked to him he wasn't sure he can get off work yet. So we will see.

[Popsgarage]

So a radius arm. Awesome. That I'll look forward to, even if I have to wait awhile.

[Stang5lgt]

Today...
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0357.jpg
I had to cut inch off the transmission output shaft to get the STaK to mate tightly.
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0358.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0361.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0359.jpg
Expedition shaft left, 3rd Gen Explorer middle, and stock right.
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0364.jpg
3rd Gen fit like a glove.
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0363.jpg

[Stang5lgt]

Had to cut a little off the gas tank support.
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0365.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0367.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0369.jpg

Drives good. The STaK is little noisy but not to bad. Might be cause I do not have a floor boot yet. The low range is awesome. I can barely keep it from moving in 5.22 low range it wants take off. LOL

[Popsgarage]

Good gawd, that thing is SEXY!!!! Lookin' good, :cool::thumb::cool::thumb:Josh.

[Beefy]

That is a sweet rig!! :thumb:

[Stang5lgt]

Thanks guys! I love this truck.

[glacierpaul]

Very nice!!

[Heather]

Awesome work! I'll bet that's a fun rig!

[jesse05lj]

this is true and if you are going to spend the big $ and get a Dynatrac the 44 and the 60 are about the same price.

[mattzj98]

this is true and if you are going to spend the big $ and get a Dynatrac the 44 and the 60 are about the same price.

U lost me again.. what are you talking about? What's true?

[Stang5lgt]

U lost me again.. what are you talking about? What's true?
Talking about money you save on building a D30 compared to D44 and if you are going to pony up to 44 may as well spend a little more and snag D60. Cause the 44 isn't much of a upgrade over the D30.

[jesse05lj]

really weird! i posted this on another post? my computer has been acting up!!!!

[Stang5lgt]

Got the boot and I put a front shaft in 5.22 low is awesome! It will climb right up and over curb with no throttle. Still have to do a little work to shift to get the boot to fit.

http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0380.jpg
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0388.jpg
Crawled right up the wifes TJ with barely touching the throttle in 5.22. Love it. I need to hit a trail now. Still had the front sway bar hooked up. The rear flex with stock leafs is awesome!
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0386.jpg
http://i24.photobucket.com/albums/c16/Stang5lgt/IMAG0387.jpg

[AccordRanger]

I love this merc! Basically how I want my sport. V8 and SAS's.

[Stang5lgt]

I love this merc! Basically how I want my sport. V8 and SAS's.

Thanks man been a busy year so far. I haven't done a ton of upgrades to the Merc it has been running great. Over 20k miles since the SAS I drive it all over the place it is my main DD. I built another rig this Summer called the Rock Ranger and still have the Merc. Also put a new kitchen in the house and all new bathrooms getting ready to put the house on the Market and move to some acreage to make more room for my business. Bought the wife 2012 F150 FX4 Ecoboost she told me I can do what I want with the Lincoln Aviator now that she has a new vehicle so get ready for another SAS Ford project already started picking up parts to build it.

Built a new bumper for the truck.
http://i24.photobucket.com/albums/c16/Stang5lgt/20120404_191817.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/Fun/00032_Capture.jpg

Merc and my wife driving Rock Ranger on Chinaman. TNT is last in line on Ford day.
http://i24.photobucket.com/albums/c16/Stang5lgt/00017_Capture-Copy.jpg

Rock Ranger won Truck of the Month last month on Ranger Station pretty cool.
http://i24.photobucket.com/albums/c16/Stang5lgt/Fun/20120713_155307.jpg
Rock Ranger on French Creek great day all Rangers that day...
http://i24.photobucket.com/albums/c16/Stang5lgt/Fun/00049_Capture_1.jpg

http://i24.photobucket.com/albums/c16/Stang5lgt/Fun/19991231_223729.jpg
Flexes ok. ;-)
http://i24.photobucket.com/albums/c16/Stang5lgt/Fun/19991231_191410.jpg

[Patrolman]

Wow, you have been busy! As soon as your are done with the work, you can stop by and put a new kitchen in my house too. :)

[AccordRanger]

I like that bumper! Cant wait to see the Aviator!