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mikec91sy 02-21-2013 11:20 PM

1 ton swap
Ditching the dana 44s and going 1 tons. Gonna try to post up as many pics as i can of the process. I was going 14 bolt rear, but decided against it and go dana 60. 14 bolts are just so massive, and i dont plan on going with a 500hp v8 in the future, so a 60 will be just fine, and ground clearance is better.

so here is how it sits before the swap.

picked up a rear dana 60 from a 78 f250. found it off craigslist for $150 with no carrier. but i am doing 5.38s with a 35 spline spool and 35 spline chromoly axles. also i am doing custom disc brakes in the rear.
disassembled the rear and cleaned, waiting for all my parts to come in the mail.

just picked up the front dana 60 from a chevy today. front rear didn't cost me anything, traded for a 77 f150 i had laying around in my yard for the past 2 years. gonna be installing 5.38s with a grizzly locker, and keeping stock axles for now. also replacing all the new wheel bearings and spindle bearings also.

since it's a passenger drop, i scored a dana 300 on craigslist for $100. gonna be gearing it with 4:1s and twin sticking it.

more pictures coming soon with progress.

cRaZy888 02-22-2013 09:38 PM

Nice project you have rolling there!
Where are you located?

Also, those front fenders, are they plastic?
They look a lot like mine (tube fender look a likes), and I have no idea what brand they are. Buddy of mine has badly rusted fenders, and wants to cut them back, and slap on the same ones I have, but mine were on the YJ when I bought it.

2xs 02-22-2013 10:39 PM

2.5 ton rockwell

That is all....

J/K nice Jeep man

mikec91sy 02-22-2013 10:47 PM

located in atco, nj. and yea 2.5 tons are nice, but theres no where to wheel anymore like that lol 1 tons is pushing it, especially driving it on the street. lol

mikec91sy 02-22-2013 10:58 PM

bunch of goodies arrived. 5.38s, grizzly locker for front, yukon spool for rear, master install kits, yukon 35 spline axles for rear, 1350 yolks for front and rear.

mikec91sy 02-23-2013 07:14 AM

Oh and About the fenders, they are stock. Lol I removed the factory flares and cut the very front, it gives it that flat fender look at no cost. Still need flares down the road but it will do for now

denisbaldwin 02-25-2013 02:16 AM

Looking good. I was all gung-ho to do 1 tons on my Jeep. I think I'll hold off and do it on another project since I have so much money wrapped up in this install as it is.

Hardcharger 02-25-2013 04:52 AM

Are you having them cut down or, are you running full width?

mikec91sy 02-25-2013 01:38 PM

Full width. Not trying to have a 10,000 dollar yj. Trying to build it on a budget, but still doing it right.

indirocz28 02-26-2013 09:21 PM

Looks like quite a project!
You will enjoy every minute of it I am sure. Best of luck with the swap and build!

mikec91sy 02-26-2013 09:22 PM

installed my gears in the back rear tonight.5.38 gears and Strange spool. just gotta cut the axles and toss them in next. hopefully install the front locker/gears tomorrow.

mikec91sy 03-03-2013 01:03 AM

made some progress with the rears.
had to hone out the rear spindles to accept the 35 spline yukon shafts. what a pain, thats all i gotta say.
cut to length axles.
disassembled front axle, resurfaced rotors at work.
front axle set up with grizzly locker installed.

mikec91sy 03-03-2013 09:32 PM

primed and painted both rear today. nothing crazy

mikec91sy 03-10-2013 08:54 PM

all painted, ready for install.
39.5s, mounted to rear.

mikec91sy 05-09-2013 11:07 AM

1 ton swap build COMPLETE!
okay I finished the build a little while ago, but didn't have time to post up the rest of the pics. but here they are!!

mikec91sy 05-09-2013 11:10 AM

time for building the transfer case. I found a dana 300 on craigslist, im installed a terra low 4:1 gear kit, and twin stick kit. I will also be modifying the shift lever to be able to disconnect the rear, and have front wheel only. :punk:

and I highly recommend NOT using milemarker hubs. the FIRST time I took the jeep out, on the FIRST hill, one of these hubs blew up. I guess my stock 4 cylinder motor is too much for these. I thought they would hold up, due to the box having a bunch of jeeps on one ton and 40s. but they are junk. spend the money for warns. don't waste your money, you get what you pay for. I upgraded to warn premiums and haven't had a problem.

mikec91sy 05-09-2013 11:11 AM

95YamJam 05-09-2013 04:38 PM


tigerblood 05-09-2013 05:25 PM

That is pretty badass looking, some day Im going to put full width 60's under mine...some day

mikec91sy 05-10-2013 07:47 AM

Thanks! and Do it! One tons are the way to go. I can abuse the hell outta those axles and they hold up.

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