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And it begins!

4K views 41 replies 12 participants last post by  AllMudd 
#1 ·
So after months of research it begins! My Dana 35 is going to be replaced like so many others with a Ford 8.8. I've needed to do this since I took my Jeep out of storage in late March. Now all the research is done the parts list is as tall as my bills. More to do but money saving time is among my problem now. I was able to locate a 97 exploder sport with 4.10s and LSD. A buddy of mine and I searched the JY here is the high desert for 1.5 hrs and found the one I wanted. After parts searching for the missing rotors, pads, caliper bolts and pulling the flange yoke off the stock Exploder driveshaft this is what I need.

-Axle is in the garage picked it up for $162.00
-8.8 axle swap kit (cheapest I've found is $127.50 at Ruff Tuff specialities)
-New PB shoes
-2 3/8" wheel spacers to accommodate the narrower axle
-1/2" shackle lift for the rear to level the Jeep out (doubt I will notice the 1/8" difference)
-75w140 only I guess is what the tag on the diff says
-1310/1330 combined ujoint (have to look into if the 95 Jeep has 1310 or 1330 the exploder is 1330) so I can use the stock flange
-And currently debating the PB cables from M.O.R.E or just make mine work
-Most of all I need to locate a good welder in my area (current location is middle of the Mojave Desert literally!)

So m list is there if I'm missing something that I need or would make it easier please help a fellow Jeeper out.


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Gotta keep this guy occupied while doing all this so it's time consuming to say the least but I enjoy every minute spending time with this little guy. I just can not wait until be is old enough to turn a wrench so I can have a helper while I do all the upgrades that are in my Jeeps future.
 
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#36 ·
Take your time with it and use all reliable resources! Make sure if you want an LSD look at the door panel and get the D2(4.10 gears) or D4(3.73 gears). And I haven't rebuilt it yet with the exception if the PB. I'm saving more & for 4.56 gears and he install kit. It is a precision Jon to regear but I'm looking at doing this myself too. Just another thing to take the time on and not rush it.
 
#37 ·
Finally got he time and someone to help me weld it all together. It's in and runs smooth! Glad to finally be back on the road. Didn't get pics of the re-install because the shop I was at was closing and the guy comes to me and says. Hey y'all gonna be done in 30 mins we close then. Well needless to say it was NASCAR style Jeep reassemble! Took 30 mins to prime paint carry bolt down hook shocks up re attach drive shaft and hook up brake lines. Oh and also clean shop and return tools! We did it, though all we had to do was bleed the brakes again and off we were. And I wanted to say that I welded some if the axle so a quick crash course on it and I welded the shik brackets on. Not to bad if I do say so myself.
 

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#38 ·
Great work! I know I would be sweating bullets putting it all back together that fast.
 
#39 ·
Ah trust me I've gone over it three times here at the house. But my buddy that was helping is a great guy and mechanic. And we are able to do stuff under pressure well being in the Military so we took the challenge head on and conquered it!
 
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