JT4x4

The Mud Pit => Wrenching => Topic started by: Flex on September 17, 2009, 04:40:48 AM

Title: Ford 8.8 swap into xj
Post by: Flex on September 17, 2009, 04:40:48 AM
So i have decided to document the build and install of my ford 8.8 axle into my jeep, i know this build has been done about a million times. But i'm doing this for a variety of reasons. First off, if at some point i start totally screwing up pls let me know. Second of all i hope this might help some one at some one at some point somewhere along the way. So here it goes.

So here is what i started with:
2000 jeep cherokee sport, 4 inch lift, 33 inch tires, no slip yoke eliminator kit.

donor vehicle- 98 ford explore 8.8, disk brakes, 4.10 gears, open diff.

So heres the plan, im going to set the pinion angle at 16 degrees, for two reason this should point the drive shaft pretty close to the yoke coming out of the transfer case. But more importantly when the jeep is lifted to 8 inchs and the sye is installed (which will happen soon after the axles go in) the drive shaft should point to the back of the transfer case.

Now for the shock mounts, the forward passenger side shock mount will be set at 2 degrees and the rear driver side shock mount will be set at 4 degrees. basically these numbers came from a guy that did this same swap. so im going to go with these unless something comes up and they dont work.

So day one begins, time to strip and grind the rust.

(http://i749.photobucket.com/albums/xx135/flexjt4x4/photo8.jpg)


But please those of of you that have done this before or know more than me about it pls let me know if these numbers seem off to you. My biggest concern is the pinion angel.

Title: Re: Ford 8.8 swap into xj
Post by: Seabee_BUC on September 17, 2009, 07:40:35 AM
When I welded up the TJ brackets on Axle's 8.8, I think we did 15 degrees...He got the numbers form Stu's Offroad.: Ford 8.8 swap (http://www.stu-offroad.com/axle/8.8axle/8.8axle-1.htm)
Title: Re: Ford 8.8 swap into xj
Post by: Flex on September 17, 2009, 06:08:05 PM
do u know what size lift he is running
Title: Re: Ford 8.8 swap into xj
Post by: gearhead1985B on September 17, 2009, 07:33:37 PM
Axle was pushing 7 to 8 inches iirc
Title: Re: Ford 8.8 swap into xj
Post by: Sandbox Sailor on September 17, 2009, 10:57:26 PM
That TJ had a Rock Krawler 7" x-factor kit and a body lift.
Title: Re: Ford 8.8 swap into xj
Post by: kirksjeep on September 18, 2009, 12:32:31 AM
Remember that leaf springs are not as easy to adjust as coils.  When I did mine I mocked it up, w/ the U-bolts and wheels/tires on the ground, full weight in the Jeep.  I bounced the bumper a few times just to make sure it was settled.  I used a floor jack to adjust the pinion so it was pointed a little higher then the slip yoke.  I never measured any angles, but I spent a lot of time making sure it was set up right. 

Depending on how you plan to get the 8" of lift will have a lot to do with your pinion angle.  A shackle lift will tilt the pinion higher then an AAL or a straight spring lift.  You have a few options, take a guess and hope it's right, install the lift and SYE and set it right, or if you do guess and it is close but not just right you can always add shims to dial in the angle.

I did a lot of little stuff to my 8.8 that aren't needed, but ended up pretty cool.  I used a truss that I bought for my D35 on my 8.8, not really needed for trussing, but it would help for keeping the axle tubes from spinning.  I welded the tubes to the housing which everyone does, but there are a few tips for welding cast to steel.  I heated the cast part before welding, welded about 2 inches at a time and then covered the weld with my welding gloves to hold the heat in and control the cool down rate for both the cast and mild steel, think BFPL curve since you are a Nuke.  I also moved the shocks up flush with the bottom of the axle which cause exhaust problems. 
here is a link to my old write up:
http://jt4x4.com/smf/index.php?topic=1121.0


Also nice General Lee Lawn Mower ;D
Title: Re: Ford 8.8 swap into xj
Post by: Flex on September 18, 2009, 06:20:13 AM
Day 2: Today i got the axle all ground down and all unnecessary things removed and got it painted up. i havent welded the tubes to the pumpkin yet which i prob should have done before throwing any paint at it, but kirk thanks for the tips on welding the tubes.

(http://i749.photobucket.com/albums/xx135/flexjt4x4/photo9.jpg)

So kirk again i think ill take ur advise/method of finding the pinion angle. i think with the jeep sitting with 4 inches of lift ill point the drive shaft slightly above the slip yoke and then after the lift and sye installed im guessing that the drive shaft will still be pretty close, fingers crossed. But worst case i go get some shims but in all honesty i dont see it being a problem.
Title: Re: Ford 8.8 swap into xj
Post by: Flex on September 19, 2009, 02:59:34 AM
Day 3: So today i got the tubes welded to the pumpkin with pretty good success. But now the build is coming to a stop until the brackets come in that i ordered from ruff stuff. But with this break in the rear i can take tomorrow to go find a hp dana 30 out of a 96-99 xj due to the larger u joints that came with those axles. Also im going to try and find dana 30 outers from a 99-04 grand cherokee due to the two piston calipers and the lower mount points for the tie rods which will alow me to go to over the knuckle steering with just a flip of the tie rod.

Kirk i got a better shot of the general for ya, i painted this when i first moved in to the house about 2 months ago, i guess mostly to let the neighbors know what kind of redneck neighbor they have without going door to door.

(http://i749.photobucket.com/albums/xx135/flexjt4x4/photo10.jpg)
Title: Re: Ford 8.8 swap into xj
Post by: kirksjeep on September 19, 2009, 03:33:07 AM
The tractor and the axle both look good!
Title: Re: Ford 8.8 swap into xj
Post by: BlacXJeep on September 19, 2009, 03:46:42 AM
Day 3: So today i got the tubes welded to the pumpkin with pretty good success. But now the build is coming to a stop until the brackets come in that i ordered from ruff stuff. But with this break in the rear i can take tomorrow to go find a hp dana 30 out of a 96-99 xj due to the larger u joints that came with those axles. Also im going to try and find dana 30 outers from a 99-04 grand cherokee due to the two piston calipers and the lower mount points for the tie rods which will alow me to go to over the knuckle steering with just a flip of the tie rod.

Kirk i got a better shot of the general for ya, i painted this when i first moved in to the house about 2 months ago, i guess mostly to let the neighbors know what kind of redneck neighbor they have without going door to door.

(http://i749.photobucket.com/albums/xx135/flexjt4x4/photo10.jpg)

BlacXJeep: Bows to Flex's tractor....... thats pretty sweet
Title: Re: Ford 8.8 swap into xj
Post by: gearhead1985B on September 19, 2009, 05:10:15 AM
Check out dean's for your parts i was there a couple of days ago and they had a few cheerokees and grands
Title: Re: Ford 8.8 swap into xj
Post by: Flex on September 19, 2009, 05:39:59 AM
yea im gonna give deans a call tomorrow im hoping that have everything
Title: Re: Ford 8.8 swap into xj
Post by: kirksjeep on September 20, 2009, 02:33:49 AM
If you find the gear ratio in an older axle, you could always swap the shafts with the axle that is under it now.  Just another option.
Title: Re: Ford 8.8 swap into xj
Post by: Flex on October 13, 2009, 11:28:31 PM
ok so i did a terrible job of documenting that axle swap but hey i think if i had anymore to worry about my brain would just give up. so today i finished bolting the axle in. As soon as i turn and drive out of the drive way i hear like a clicking noise, as long as i drive straight i dont hear anything but any time i turn i hear the clicking/clunking noise which is proportional to the speed at which i take the turn, any advice would be great.
Title: Re: Ford 8.8 swap into xj
Post by: Flex on October 13, 2009, 11:47:22 PM
by the way the sound is coming from the rear end, and it will shift from side to side depending which way i am turning.
Title: Re: Ford 8.8 swap into xj
Post by: calvynandhobbs on October 13, 2009, 11:56:40 PM
Is the emergency brake cable too tight and pulling from side to side with body roll in the corners to where it partly engages around corners? How long has that axle been sitting before you put it in. Could the outer bearings be dry and when pressured in corners causing a clicking? I'm just thinking out loud.
Title: Re: Ford 8.8 swap into xj
Post by: BlacXJeep on October 14, 2009, 12:48:11 AM
weird, I am hearing a simmilar noise coming from my rear end at low speeds. Its like a popping clicky noise Considering I just did a swap as well, it could be somethiing simmilar. I was thinking maybe it was the new U bolts settling. I'll keep you posted about what I find out.
Title: Re: Ford 8.8 swap into xj
Post by: gearhead1985B on October 14, 2009, 12:49:25 AM
What type of locker did you put in could that be the clicking noise
Title: Re: Ford 8.8 swap into xj
Post by: calvynandhobbs on October 14, 2009, 01:24:22 AM
What type of locker did you put in could that be the clicking noise

Nate, I forgot all about you putting an Aussie in the 8.8 (duh). It's supposed to make that noise when going around corners. If you read any articles about autolockers they will tell you that there is an audible clicking as it ratchets around corners. Aussie is actually supposed to be one of the quieter ones. You may notice the noise subside a little as you drive into the break in period, which I think is 500 miles.
Title: Re: Ford 8.8 swap into xj
Post by: Flex on October 14, 2009, 03:13:20 AM
ok i did some searching and realized that it is supposed to make a quite clicking sound and i think my terrified mind make it sound louder than it was bc i drove it around town with the window half way up and the music barely on and never heard it , so i guess that means its good to go. and since that was the only problem i had it was time to pull the front axle, so within 2 hrs i had the front axle out and the lower control mounts tacked onto the new axle ready to take and get fully welded on since my welder blows. So hopefully tommorrow i can have the new front axle in and the new front bumper put on and ready to go to mabell as long as that still going to happening.
Title: Re: Ford 8.8 swap into xj
Post by: kirksjeep on October 14, 2009, 04:32:39 AM
The Aussie will click and clunk for about 300 miles or so and then it breaks in a little and you will forget it is even back there, except when you lay into the gas in a turn, then hold on!!!  I forgot this morning when I took my YJ to work, good thing I have the sway bars connected or I may have rolled it on the street.
Title: Re: Ford 8.8 swap into xj
Post by: calvynandhobbs on October 14, 2009, 02:16:15 PM
The going from unlocked to locked in the middle of a corner can be scary if you're not paying attention. I have found with my welded rear on my TJ that if I give it too much gas starting from a stop going into a corner that I lift the inside front tire off the ground and go around the corner on 3 wheels. I think it was Flex that noticed it this past Saturday when we wheeled after the cook out. I had to punch it to make a left turn yesterday in New London and I could see by the looks on peoples' faces that I did again yesterday.
Title: Re: Ford 8.8 swap into xj
Post by: PaulW on October 14, 2009, 07:58:55 PM
Im going to have the 220v welder out 2moro night burning my trailer hitch. I can burn the mounts at the same time if you want.
Title: Re: Ford 8.8 swap into xj
Post by: Flex on October 15, 2009, 04:07:00 AM
Im going to have the 220v welder out 2moro night burning my trailer hitch. I can burn the mounts at the same time if you want.

thanks for the offer but i got them welded before i saw ur offer.
Title: Re: Ford 8.8 swap into xj
Post by: PaulW on October 15, 2009, 02:08:23 PM
doh! day late