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Old 07-01-2013, 12:13 AM   #1
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And it begins!

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.


Attachment 267419

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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Old 07-01-2013, 12:37 AM   #2
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Good times! And good luck on your hunt for a welder. Always nice when the worry about the D35 goes away,

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Old 07-01-2013, 10:35 AM   #3
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cant wait to see the progress, good luck!
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Old 07-01-2013, 02:39 PM   #4
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You may not really need those wheel spacers. After I got mine in the difference was so small it was hard to see.
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Old 07-01-2013, 05:03 PM   #5
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Originally Posted by rykemc View Post
You may not really need those wheel spacers. After I got mine in the difference was so small it was hard to see.
Ill check this out once its all centered and stand back and look.
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Old 07-05-2013, 05:12 PM   #6
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Update: Got all my stuff situated so it was time to start. I got lucky on my flange for the rear driveshaft. Did more research and my u joint was he same size as the Exploder. So easy fix gotta love it!

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Once that was done it was time to tear down and start replacing the PB shoes. Then off to cutting off the stock sway bar and spring perches.

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Gotta love how easy it is with a good cutting wheel and a BFH! Once I get the perches cut off I will grind down the rest so I can pressure was it and get it prepped for welds. Found that Ruff Tuff has a 18% discount on all stuff till Monday. So I'm gonna save the $25 and cash in on the deal.

Now time for removal of the Dana35. The PB cables and brake lines gave me the biggest trouble. Letting the brake lines sit in Liquid wrench for a couple hours hopefully that will help.

And anyone else done this swap? Got a ? are the axles supposed to slide in and out of the housing about 3/8" on both sides? It seems to be normal but not sure. Thanks
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Old 07-05-2013, 05:46 PM   #7
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That axle play is normal.
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Old 07-05-2013, 05:55 PM   #8
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AllMud,

Looking to do that swap as well on my YJ, are you gona use the "U" bolt plates from the explorer? seems helpful since has shock mounts.
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Old 07-05-2013, 06:30 PM   #9
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AllMud,

Looking to do that swap as well on my YJ, are you gona use the "U" bolt plates from the explorer? seems helpful since has shock mounts.
I wish I had kept them when I went to the JY. But now that I am cutting off the perches, I'm not going to reuse any of the stock mounts. I am buying the RUFF TUFF kit that's on sale right now.
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Old 07-05-2013, 06:44 PM   #10
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Tagging along. I have an 8.8 w/ 4.10 gears and disc brakes sitting in my garage waiting until I get the balls to do this. For now, I'll be following along. Please document EVERYTHING!!!!
Are you putting in a slip yoke eliminator?
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Old 07-05-2013, 07:11 PM   #11
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Jerseydriver- good deal man. Don't be scared honestly just know that there is many write ups about this just research research research. I read everything I could before jumping in head first! I'm enjoying getting the wrench time go let me tell ya! My Jeep was in storage from Dec '04-Mar '13. So it was about time to do the major swap. Do you know if your 8.8 is with the LSD? If not look into locking it you'll love it.
And not sure if I need the SYE yet I've still got to mock everything up and find out. I am pretty sure I'm gonna have to at least get a longer driveshaft but hoping not. I have a 4" lift with stock shaft right now and no issues. Her was my angle before the swap.

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So I'm crossing my fingers!
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Old 07-05-2013, 07:46 PM   #12
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No, it's not a LSD. Was thinking about throwing in a Spartan.
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Old 07-05-2013, 08:58 PM   #13
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There ya go. Here is what happened to my Dana 35, I just took my diff cover off and discovered this was the noise I was hearing!
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Old 07-07-2013, 02:43 PM   #14
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Now the 8.8 is cleaned up its ready for the brackets to arrive. I ordered the RUFFSTUFF swap kit cost $127.50. Got to love stuff on sale! Saved over $25 on the 4th of July sale weekend. Hoping I get the kit on Monday or Tuesday so I can continue working and locate a good welder. This swap is much easier than it sounds. I think the hardest part is doing all the labor.
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Old 07-07-2013, 05:29 PM   #15
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Nice. You gonna throw on a new differential cover?
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Old 07-07-2013, 06:04 PM   #16
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Old 07-07-2013, 06:45 PM   #17
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This is a great thread wasomma. And yes a new cover will be in soon. I will need to regear it to 4.56 and it will be on there then. But for now so I can drive her around its gonna be 2wd only!
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Old 07-10-2013, 09:06 AM   #18
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Ouch!!!
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Old 07-10-2013, 01:33 PM   #19
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Ouch!!!
????
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Old 07-10-2013, 01:58 PM   #20
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????
I'm hoping you have enough clearance for the driveshaft. I plan on getting a RC 4'' lift kit for my YJ. I have about 2.5 lift right now and no problems except for an old rear U-joint that needs to be replaced but I have a ton of space and NO vibrations going down the road at even 75.
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Old 07-10-2013, 03:53 PM   #21
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I've got plenty of clearance. When I put my 4" lift on and the 1 1/2" TC drop the dshaft barely moved and I had no vibs whatsoever. The only thing that I'm worried a out is if he dshaft is long enough since the 8.8 is almost 2" offset to the right.
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Old 07-13-2013, 09:08 AM   #22
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I'm thinking of getting RC 4'' lift and RC 1.75'' body lift. I have mostly stock everything underneath just want it to work but don't know how to install and body lift and the pros/cons of it. Still have more questions but don't want to swamp your topic LOL
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Old 07-13-2013, 11:09 AM   #23
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It all depends in the person I think. Most go with SYE when they lift to 4". And also the BL is easy you just have to locate and remove all the stock body mount bolts. Lift the body with a jack or leverage and slide in the new body bushing. Then there are a few things you have to relocate. Not sure exactly what but I know there are some things. The BL kit will come with directions that should help quite a bit. I am waiting for another budget to do the BL I'm only going with 1". But I need more than most ppl. Currently my starter power cable is barely long enough to touch the starter so that would have to be changed and I would have to cut a bigger hole for my shifters so it won't bind on the body.
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Old 07-13-2013, 11:39 AM   #24
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It all depends in the person I think. Most go with SYE when they lift to 4". And also the BL is easy you just have to locate and remove all the stock body mount bolts. Lift the body with a jack or leverage and slide in the new body bushing. Then there are a few things you have to relocate. Not sure exactly what but I know there are some things. The BL kit will come with directions that should help quite a bit. I am waiting for another budget to do the BL I'm only going with 1". But I need more than most ppl. Currently my starter power cable is barely long enough to touch the starter so that would have to be changed and I would have to cut a bigger hole for my shifters so it won't bind on the body.
I'm not sure if your shifter set up is different but I've done a few one in BL's and only thing I had to relocate was the radiator because of then fan/shroud alignment. I'm a fan of 1" for that reason alone. You can usually get it done within 2 hrs.
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Old 07-13-2013, 11:56 AM   #25
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I'm not sure if your shifter set up is different but I've done a few one in BL's and only thing I had to relocate was the radiator because of then fan/shroud alignment. I'm a fan of 1" for that reason alone. You can usually get it done within 2 hrs.
I've read around that when you do a 2" or more BL you have to cut the shifter spot bigger. And I figured since I have the TC drop already 1.5" or so (haven't measured it but that's what it looks like) and then add the 1" BL . I think it may be an issue. Honestly not sure why my starter cable is short but my brother put a bunch of hours in on my Jeep for me while I was deployed so he might have needed to shorten if because of corrosion.
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Old 07-14-2013, 08:01 PM   #26
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Now I have the job of setting everything where it needs to be and clean all of it up in preparation for some good welds! And what a beefy kit! Love the little logo they send I need to find somewhere to put it.
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Old 07-14-2013, 08:01 PM   #27
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Forgot to post this.
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Old 07-18-2013, 01:31 AM   #28
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Ok for those of you following this, I got the a me under the Jeep. Took some muscling since I'm a little guy. But it's there none the less. I had to grind down the leaf perches to get it with a little gap between the bracket and a me housing so it can be welded good.

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After that got the u bolts on and it centered. Kinda funny I had it just about where it needed to be at 5 1/4" from the leaf perch to the axle flange.

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Need to cut these down once everything is measured 10 million times, welds are solid and I'm ready for the road.

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And the drive shaft fits but I have some questions on the leaf perches. There are three holes see here.

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But my question is why are there three? Do you have to use the middle one? Or are they there for you to choose? Just trying to do this once since money is not on anyone's side in the Jeep world.
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Old 07-18-2013, 06:42 PM   #29
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Got everything where it needs to be now. Everything worked out nicely. Got my rear drive shaft at 9 degrees. Looks good and even had a buddy that does custom builds come take a look at he was impressed! So now just waiting on a welder to tack everything up so I can bring it into work. My work has a welder that's perfect but it is a little to big just to throw around.
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Old 07-18-2013, 07:26 PM   #30
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Looking good man, dosnt look like your drive shaft length changed any? Did it?

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