update 1-31 -Axle Swap Progress with pics

[kirksjeep]

Were back from MD, so it was time to get working on the YJ again.  I finished the brakes on the new Dana 30 and bolted the tire back on.  I also managed to get the Dana 35 out of the rear.  The Dana 35 is SMALL!!!  I can pick the Dana 35 up by the axle truss and move it around with out much problem.  I would guess that it only weights 120 lbs or so.  The 8.8 is very heavy, I can only move it with a jack or dolly.  More to come.

http://s380.photobucket.com/albums/oo242/kirksjeep/Axle%20Swap/?albumview=grid

[kirksjeep]

No, new pics yet, but I have decided to add a few "custom" touches to the 8.8 install.  I decided to make my own U-bolt skid plates using the stock Explorer plates as a base.  After 30 minutes of trimming I managed to make the stock ones square and flat.  I then chopped up a section of an old bumper I had to get some flat steel.  After some welding and grinding I set up my new drill press to make the holes for the nuts to pass through.  I drilled out the bottom big enough for the nuts, but I forgot to make them big enough to get a socket into.  I don't have a 1" drill bit, so I need to pick one up and make the holes a little bigger. 

I also cut the axle truss off of my Dana 35 and mocked it up to fit the 8.8.  On the LSD 8.8 there is a sensor on the axle housing, so I removed it and made a small plate to bolt onto its place.  I then ground the sensor guards, which wasn't necessary, but I already had the grinder right there.  The last part I got done was to cut the outer lip off of the disc brake backing plate.  The stock ones have a 1" lip all the way around, that are known to collect mud and little stones.  I heard that most people just remove the backing plate, but I wanted to keep it, but just make it less likely to pick stuff up.  It now looks like the backing plate for the front disc brakes.  I only got one side cut off, so far, so I have some more grinding to do.

When I get the U-bolt skids done and finish cutting the lip off of the other backing plate I'll post up some more pics.

[PaulW]

nice

[calvynandhobbs]

Sounds like your making progress. You will be in good practice for when you sell me the other 8.8 you have and help me get it installed in my XJ.

[Axle]

Kirk!!!  http://newlondon.craigslist.org/bar/980457524.html

[HOT-ROD]

hook it up kirk. easy money, i'll help you weld.

[kirksjeep]

I already wrote the guy back to make sure he has all the needed parts.  Depending on how complicated he wants to make it, I may take the job. BUT, I need to get mine finished first!

[dirt_kx]

no i dont have all the parts yet i wasnt expecting to do the swap yet but i let my freind use my jeep and he blew my dana 35 so i figured i should just do the swap i dont mind waiting till your done with yours if you would like to do it i would also be willing to do what ever i could to help out

[Axle]

Welcome!  Introduce yourself on the General thread.  I was the one that responded to your Craigslist post. 

[kirksjeep]

dirt_kx, I have a spare Dana 35

Depending on how much snow we get I may be able to put some more time into the swap tommorow.  I'm going to pick up a 1" drill bit tonight after the meeting, so I can finish up the U-bolt skids.  Hopefully the Tera flex shock relocating bar and lower adaptors show up before the weekend, so I can mock them up and get everything in place.

[kirksjeep]

I picked up a 1 1/8" hole saw from Lowes on the way home from the meeting.  After doing a little searching for the right drill press speed, it turns out that most buggy builders recommend Lennox Bi-metal hole saws, sold at Lowes, so I lucked out and bought right stuff the first time. 

[kirksjeep]

The first U-bolt skid is done.  It took about 5 hours from start to finish.  The second one is about 2/3 done and only took 2 hours to that point.     The hole saw worked awsome and after 8 holes the teeth are still very sharp.  I also got the Tera Flex shock bar and mounts in.  The strange thing is, I ordered them from Oconee Off Road (Sale, %15 off and free shipping), but they were shipped from Quadratech.   I paid $107 from Oconee and Quadratech wanted $107 for just the bar, plus $25 for the lower mounts and shipping.


LINK TO NEW PICS
http://s380.photobucket.com/albums/oo242/kirksjeep/Axle%20Swap/?albumview=grid

[kirksjeep]

The NFL Playoffs are interfering with my progress.  I did manage to pick up some small hardware stuff like the bolts to attach the drive shaft to the 8.8.  After the Ravens game I am headed to the garage for a while. I don't plan on leaving until the 8.8 is in and mocked up with tires, shocks, and the drive shaft

GO RAVENS!!!!!!.

[PaulW]

word

[kirksjeep]

I ran into my first snag last night.  I got the axle in position, drive shaft on, wheels on, off the jack stands, but the shocks are becoming a PITA.  The Tera Flex shock relocation bar causes the passenger side shock to hit the tail pipe.  It looks like my only option is going to be to cut my tail pipe off just behind the muffler and try and modify it to work with the shocks. I figure worst case, I might need to get a new tail pipe bent up and welded on.  I won't have much time to get to it until Friday.