SAS Chevy K2500 Walkaround

1998 Chevrolet K2500
Extended Cab Short Bed
7.4L 4L80E NP243
1989 Ford F350 Dana 60 front axle
Offroad Design SAS kit and crossover steering
Offroad Design custom 2" lift springs
WFO Shackle flip, shims and axle re-centering spacers, u-bolts and frame plates
Bilstein 5165 shocks
OBS Ford F250 shock towers
Nitto 315/75/16 tires
5" lift front, 5.5" lift rear
OTHER VIDEOS OF THIS TRUCK
Build Video:
• Chevrolet K2500 STRAIG...
Update and FAQ:
• Straight Axle Swapped ...

[@DaveScottADV]

Looks so tough with the tires tucked in and the black wheels. Very utilitarian.

[@alb2571]

Thanks for posting man, nice ride and build

[@solohopper]

Let’s go wheeling!!! Always down to meet other full-size owners.

[@hammerhead19able]

Beautiful red horse. Love it!!

[@JesseG085]

Those PIAAs are dope.

[@scottlilly4091]

Good lookin truck!

[@KC-7mm]

Sick truck

[@raptor-yg1ek]

Sweet setup man! Hoping to do something like this to my Tahoe soon

[@Calikov762]

I was considering doing this SAS to the two door tahoe I had! Would be cool to see. Make sure to make a video if you do yours!

[@raptor-yg1ek]

@@Calikov762 that's awesome, I for sure will!

[@SDRacing88]

@@Calikov762 I plan on this with my 2 door! Love your truck!

[@erscustoms911]

Nice work

[@whodatnunyabiz6050]

Looking at doing that same kit for my 99 K2500 Suburban 7.4. Talked with those guys today and looks like you have it all done the way I was thinking. Very nice setup! Do you have this on any of the forums?

[@Calikov762]

Yeah the guys at ORD are very helpful. No I don’t have this posted up on any forums, I did have a build thread on a k1500 I straight axle swapped in 2012 on FullSizeChevy forums but it got washed away when they redid the website. If you have any questions you can DM me on Instagram @calikov

[@whodatnunyabiz6050]

@@Calikov762 will do. I’m not on there often but I have an account. Lol. Have to see what my wife has our name at or it might be under mine. Will look you up!👍

[@hugocastro9314]

What’s the mpg with a sas ?

[@Calikov762]

10mpg average, with the 7.4L vortec and 4.10 gears on 35’s. My old Chevy that I also straight axled had a 5.7L vortec and same tires and gears... got 10mpg too lol the difference is this one tows way better

[@franklindunn1059]

is there an engine cross member you had to completely remove it up to the motor mounts right? So you had to fab another one or make a skid plate ? I was told that it gets in the way of uptravel in a low lift SAS chevy. Just curious how you tackled that obstacle

[@Calikov762]

I left the front part of the lower control arm mounts/crossmember intact. I had to trim a bit off the back to clear the crossover steering. I have 36.5” spring pad width and the leafs only contact at full bump which isn’t really an issue. If you have 32.5” spring pad width you will have to trim the corners off the crossmember.

[@franklindunn1059]

@@Calikov762 thanks for the info

[@lucasharms5815]

I’m about to do something similar with mine using a 90 Ford kingpin Dana 60 did you leave you outters all stock? If so what lines did you run for the brake lines

[@Calikov762]

Stock outers with all new bearings and seals, u-joints too. Only thing not stock is the crossover steering arm on the passenger side and the Yukon hardcore hub lockouts. The dual piston ford brakes work well with the factory 2500 hydroboost master cylinder. Offroad Design made the extended brake line kit I’m using (made for GmT400 to ford front brakes)

[@andyrivers9423]

wouldu say the truck drives smoother than stock suspension? i have this truck and im just tired of replacing front end part and it steering and riding like crap

[@Calikov762]

The front is softer, if you want your IFS to ride smoother removing the sway bar would help. I wasn’t going to replace the ball joints a second time since I owned it so I did the SAS lol

[@kevinwest3689]

I would like to do this as well, (I think) I have a 93 1/2 ton short bed, 6 inch suspension 3 inch body I bought a 2004 Chevy 2500 HD and swapped in the 6.0 ls 4l80e I also had swapped out the weak 10 bolt for a 6 lug 14-bolt semi float put a Detroit truetrac in it with 488 gear with intentions of going from my 35 to 37 inch tires, haven't put gears in the front yet, yesterday I took the weakling little front differential out, had to grind a small triangle spot on the 2500 front 9.25 differential, and shave a piece on the frame about 7/8", still have to modify the passenger side bracket but I have to take the oil pan out to get the two bolts out, so since I don't have the money to buy the gears right now, I disassembled my CV axles so I could run it without the front differential until I decide/ can afford, custom CV axles are $1150 EACH Yikes! Front gears- Locker- compressor $$$ 5,300 may or may not need to shorten my drive shaft and inch. How much does it cost for sas... ruffly?

[@Calikov762]

@@kevinwest3689 if you put a locker in your IFS front diff you can kiss your CV’s and maybe the aluminum differential housing goodbye lol. Trying to modify the IFS to be stronger is not worth your time, it doesn’t hold up to offroad abuse anyways. Tie rods and control arms bend, the ball joints break easy… you’d have to build some custom ultra-4 style control arms and fabricate knuckles to handle 37’s on a full size truck. My straight axle swap costed roughly $10k and thats without tires, only regearing one axle, and no locker. You can do an SAS for more or for less. Check out some threads on pirate4x4 or FullSizeChevy about SASing a GMT400. I recommend you go to Offroad Design’s website and look at their complete SAS kits they range in price depending on what axle you use and what springs you want. You can get a 1977.5-1979 ford dana44 high pinion off an f250 and you can run chevy knuckles/outers that would match your 6lug pattern on your 14-b SF for a nice heavy-halfton build.

[@kevinwest3689]

A lot of what you said makes sense, but not all of it. People that race with those independent front suspension, desert rally and so forth, the locker is what saves them. Guy said he's never had a case break. No sudden shock when they're locked together, I appreciate you responding, at the price range you're talkin about, I better stick to my smooth riding good turning radius ifs, I don't plan on climbing boulders, not that there's anything wrong with it, they are guys that run Pro sled pulling trucks and drag race that have intercooled turbo 1000 horsepower, and ifs.. by choice. Love your truck" good job 👍

[@mytube572]

Beautiful truck, so are you running 40” inch tires? Also on a full turn do the tires rub on the springs? I have a 95 suburban I want to do the same swap on and I don’t want to pay crazy$$ for the 78-79 narower spring perch dana 60

[@Calikov762]

Thanks. I have 35 inch tires. 37’s will rub the leaf springs... so you lose turning radius with bigger tires on the 36.5” spring pad width. If you’re planning on running 40’s and want to use a 1980-present dana60 you can do a 3 link or radius arm suspension for more tire clearance

[@hilowtrucks]

Have you had any problems with death wobble using your factory steering box?

[@Calikov762]

I have had no death wobble. The sector shaft bearing on my steering gear was a little loose and the bigger tires killed it pretty fast. I put a PSC Big Bore steering gear in it and I run a steering stabilizer so the steering is smooth and slop free. I don’t have a track bar though, so there is some “give” side to side with the leaf springs which makes you have to put more steering input in than most people would be used to.

[@jimmycokeanhour5196]

This build turned out super clean I'm doing the same swap on my truck (1998 k3500 crew cab long bed diesel) I am using a 1986 kingpin d60 and the off road designs kit but with stock height k30 diesel front leafs have you ran into any problems with your swap yet? Also what frame plates did you use?

[@Calikov762]

Thanks! You may run into clearance issues between the leaf spring and the frame without lift springs, also limited up travel. I have 2” lift springs and it’s a little close. It’s OK you can always notch and box it back in. The frame plates are by WFO, a huge time saver!

[@jimmycokeanhour5196]

@@Calikov762 thanks for the info !

[@stephenmckinley8855]

what are you referring to when talking about it being close clearance with only 2 inch springs??

[@1badpiter458]

How is it drive on the road without any swaybars? Is it daily drivable?? Sweet build though 👌

[@Calikov762]

Thanks! I could daily it but my Yukon GT is more fun in commuting traffic haha. It’s a comfortable ride as long as you are OK with a bit of body roll. I have the stock 3/4 ton springs out back which keeps it flat when towing, but unloaded the front likes to lean a bit. I’m probably gonna get a soft anti-rock sway bar that way it helps keep it flat but not making it a stiff ride like the stock sway bar. Stock sway bar is way too stiff!!