Ok..
My truck will be going in as I start to take it apart and replace the IFS with a 3-link suspension, using a D44 and coilovers.

For you guys that have done a SAS, do you have any advice / input on those gotcha's that you encountered, things that you would like to do (in hindsight) and, if you had it all over to do again, what would you address as part of the prep/build up process?

I have absolutely no experience with SASing a truck but I just can not see doing this with a D44 no matter what you put inside it. If I was to spend 3 or 4 gs on SASing my shit I think that I?d spend the extra $ and put an ARB equipped full-width D60 up there (along with a Antiwrap/Traction Bars in the back with my springs, not applicable on you truck) and just have that shit drag the rest of the truck through well...anything.

are you talking about buying a kit or fabbing your self up a 3link setup? why run coil overs and not just a standard coil what kind of wheeling do you do? need more info then u want to sas your truck

The D44 going in will be completely rebuilt with new gears, shafts, ends, etc (all already in transport). So, there's not going to be too much left of the original D44 to make it look like it once did.

That will include an ARB selectable locker.

While a D60 or looking for a 1-ton would be optimal, the D44 was there and can be upgraded if I blow out the parts that I have too easily.

But Tom, you're right.. to do it and spend the bills that are needed, cutting corners is stupid..That's why I'm upgrading the internals, shafts and ends from the start.. But, I am already thinking about what is next.

Ether TC gears or a new TC.

Tom.. TC gears are on the plan. I'll be talking to Dave about that soon enough as I want to put 35s on and gears are going to be needed at some point soon.

Bronc... it's a Clayton kit that will be meshed with other parts / pieces to make things work. I'm doing coil overs because I want to keep things simple so that I can either run into the engine bay (likely) or get a hoop in place that will allow for both a long extension that will allow me to keep wheels on ground as well as to keep me from stuffing the tires too far in to cause body roll.

WTF just get an Atlas Twin Stick. Weee Hah!

that would be nice..
but, that's pricey

IMHO there's no reason to go with a D60. We don't have that kind of power in our trucks and the extra rotating mass will just suck up power.

The D44 is plenty stout for our application.

Good point.
If my engine goes, I probably would look for a straight swap.

How much of the Clayton kit are you using? You say you're doing a 3 link but the clayton kit is a radius arm suspension.

Just wondering if you're modifying the Clayton kit to be a 3 link as I can tell you there were a lot of surprises when I did my 3 link.

The kit (for XJs) can be set up as a 3-link, so I'll be going that route with a pan hard bar.

I expect that the big surprises will be on the end near the transfer case / transmission since I'll need to re-think the supports.

if you are running a wristed radius arm setup, it essentially becomes a 3-link when you pull the "wrist lock pin"

thats the route i'm going. 6:1 atlas doubled up behind the stock t-case = 12:1 when in low/low