Given that my SAS has about 300,000 miles on it I guess I can't complain a lot but the timing sucks pond water. I've been trying to track down a persistent noise for the last two weeks and I finally found it last Tuesday. The front frame had cracked in two right at the rear of the Ford spring bucket. Thankfully I found the break BEFORE this became more than a large irritation.
When we did the SAS eight years ago we discussed reinforcing the frame horns but decided it wasn't really necessary since I wasn't doing any serious crawling with my Sport back then. So, yea, that was a stupid decision.
I wish I had a smoking gun that I could point my finger at but it appears that it's due to just general wear and tear. The crack and break was even all the way around. Nothing is bent or out of align and there's no indication of any unusual torsional stress. It appears that the horns are just not quite strong enough for long term abuse.
So, I guess the moral of this story is if you're doing a SAS make sure and reinforce the front frame horns. Especially, if you're planning on long travel coil-overs or leafs instead of a radius arm setup.
You can just see the crack just behind the spring bucket.
This is where the break occurred. Weld held but the frame metal broke.
-------------------- '97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 228:1
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 3-link/SAS project
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