Tech Articles

Ease of installation...

Follow up:

Calmini
If you are ready to take your Xterra to the next level, this is the only system that can take it there. We are happy to release the first kit of its kind for Nissan vehicles, the CALMINI Solid Axle Swap. This kit is over 85% bolt-on with the only welding to occur on the donor axle. Our complete system allows for the entire removal of the stock IFS system and a full replacement, with a full center skid, with a solid axle out of an early model Jeep Wagoneer. The donor axle this kit is designed for is out of a 1980-85 Jeep Wagoneer model Dana 44 (D44), with a driver's side drop and a non-vacuum actuated disconnect.

This by far the easiest way to SAS an Xterra or Frontier. If you have access to a plasma cutter and a good 220v welder this is a one day project w/a couple of guys.

Now the nitty gritty...

High Points

* VERY EASY TO INSTALL
* Flexes Well
* Front Sway bar can be installed
* Skid Plate covers the vital areas Tcase/Transmission

Negatives

* Cost... but it is the same no matter how you go about it. Swapping out the IFS is NOT Cheap.
* Lower bracket on the Track Bar could use some bracing
* Stock Nissan wheels 15" will not work... FYI they will hit the brake caliper & rub on the Tie Rod. Get some 16s with some offset to avoid issues.

Other Parts you will need, not included in the swap kit.

* Front Axle (80 - 85 Grand Waggoner Drivers side drop w/o vacuum disconnects)
** D44 warn hub kit... most of these axles do not have manual hubs.
* Coilover Shocks
* Front Driveshaft
* Front Sway Bar (somewhat optional)
* Rear Leaf Springs
* Front Drive Shaft Adapter Plate
* Maybe Gears for the axle... this will depend on the gearing you want to end up with.
* Optional - Spacer for the front axle... it is narrower than the stock axle.

Thoughts - My opinions and ideas

Coilovers
OK first of the Coil Overs... no these are not cheap. Do you have to use the ones form Calmini? No you do not I would recommend looking around online for Ranchos adjustable Coil Overs (RS9000x) this way you can adjust the valving for the vehicle.

If you want the best flex out of the vehicle get the reservoir coilovers, this allows more droop/flex than standard units.

Drive Shaft/Axle
Find a local shop to build one for you. Or even call up Tom Woods www.4xshaft.com.

It will be cheaper. Also keep in mind it will only take the shop a week or less to build a shaft for you. So finish everything up then get your measurements after it is done.

You will also need an adapter plate for the front of the Transfer case. This will adapt the Nissan bolt pattern to a sandard spicer pattern.

All SAS systems will need this. www.Grassroots4x4.com or www.4xshaft.com.

Oh and dont forget the D44 Hubs... all of these axles come with slugs in the front so they are always engaged. Replace em with the hubs but hold onto the slugs... why? Well if you break a hub on a trail you can put the slug back in and it will be engaged again so you can have fun the rest of the day.

Rear Leaf Springs
Now of course you are raising the front more so you have to get the rear to match.

Get a set of springs made to match YOUR vehicle. Call up Alcan Spings in Grand Junction. They will ask you a TON of questions about your vehicle then build the set to those specs. I think you will be much happieer in the long run.

Anti-Sway Bar
Is it necessary? If you want the best street ride possible then yes, it is.

This is available from Calmini and does make a HUGE difference in on road characteristics.

IFS Removal
OK you are not gonna get much money for anything... face it they are used parts and unless you have upgraded IFS how much trouble is it worth?

Unbolt the Driveshaft
Unbolt the Rear crossmember
Unbolt the Control Arms
Cut off the last IFS section and just drag it all out in one piece

Tyler yanking out his busted up IFS.

God he was happy he was not going to be fixing that anymore.

Track Bar Gusset
The Track Bar Mount on the D44 could use some gusset in my opinion. I know a few guys running it the way it came but I would just like more steel there to hold it together.

A simple pice of steel there and a notch for the track bar mount will add a ton of strength.

Make sure... MAKE SURE you read and reread the welding instructions in this area!!! I would throw that gusset on too.

Final words

Going on a couple years now of running it and I have to say no complaints. It has done awesome in all conditions (Rocks, Sand, Snow, Ice, Mud). Its also allowed me to get into areas I would not have tried before due to the truck not flexing well enough.

Also this system is far beefier than IFS, some hits I have taken on rocks I KNOW would have broken Tie Rod Ends or much worse.

Calmini Manufacturing
http://purenissan.com/solid_axle_swap2.htm

You can also purchase it through All Phase Offroad... normally a little cheaper.
http://allphaseoffroad.com/