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64panhead 11-01-2008 10:13 PM

ford 8.8 swap into 97 tj
im going to put this here and hopefully the mods will move it to the new sub forum that i hope they are working on:D well anyways im swaping a frod 8.8 out of a 94 for explorer i will be posting up of how its going and of what im doing with it.

plans for axle are

shaved bottom
heavy trussing integrated with brackets for tj links
rebuilding from drum to drum with new gears
currie diff cover
mini spool

if there is anything anyone suggest pleas let me know

64panhead 11-01-2008 10:22 PM

i just went and got some pics

the factory perches and sway bar mounts

before pics of shaving

1BLKJP 11-02-2008 04:21 AM

Remind me again when we get the new section up and I'll move this over.

The only thing I can think of that you didn't mention might be a C-Clip Eliminator kit from Superior for the 8.8. Gets rid of the C-Clip which is really the only weak link of the 8.8 (although to this day I've still never seen a c-clip break on this axle) and gives you back the 1/2 inch you give up from the TJ axle to the 8.8.

Are you planning on keeping the drums? I only ask as informational because either way the 8.8's drums are bigger and stop better than the brakes on the 35.

64panhead 11-02-2008 06:00 AM

i will check out that c clip eliminator your talking about. cant wait to see what you guys put up for a new section:punk:

timritchieblue 11-02-2008 10:55 AM


flattietj 11-02-2008 02:03 PM

why not a disc 8.8? they r everywhere

64panhead 11-02-2008 02:10 PM

all the junk yards neer by wanted like 3x as much for a disc 8.8. and when i dont care about disc anyways it wasnt worth it to me. besids i was able to trade some junk for this junk

64panhead 11-02-2008 08:54 PM

ive been reading that some of the pre 96 8.8s had 27-28 spline axle shafts. this was buggin me so i just had to go out and pull a shaft and look for my self.and holy s@#t the shafts are big and they are 31 spline. i took a couple of pics just for fun

64panhead 11-04-2008 09:36 PM

i started cutting brackets off of it tonight and ground them down. not much going on till some money comes around next week for some steel to begin with the building the 4 link brackets. i will record all the measurments i get for a stock wheelbase short arm tj so the next person might benefit from it a little
here is a couple of pics but nothing big

jeeperman 11-05-2008 06:50 AM

Looks like it is coming along pretty well so far! Keep the updates coming!

whitebuffalo 11-05-2008 09:00 AM

the 27 splines were on the rangers, so i've been told.

are you going to weld the tubes where they go into the pumpkin?

64panhead 11-05-2008 02:29 PM


Originally Posted by whitebuffalo (Post 279586)

are you going to weld the tubes where they go into the pumpkin?

yes i am and i hope to be doing this tonight:punk:

GrnTJ 11-05-2008 04:06 PM

Ive heard mixed reviews on welding the tubes to the diff. The welds can crack if you dont use the right type of welding rod. This is because your welding cast to steel and they have different properties obvisiouly. Most people say it holds. Are you going to truss it? That would help prevent the tubes from spinning too. But in all honesty, its pretty rare for an 8.8 tube to spin anyway. All in all it looks like the project is comming along well. Keep up the good work:punk:

whitebuffalo 11-05-2008 04:39 PM

i didnt weld mine bc im low powered :flipoff:

i would think 7018 rod done in several intervals (to prevent warping) should work though.

GrnTJ 11-05-2008 09:01 PM

Yea, thats a good rod to use but ABSOLUTLEY tack each side before you lay down any kind of decent sized bead. And make sure to alternate sides and let it cool a bit between beads. Warping a tube would really suck!

64panhead 11-05-2008 10:00 PM

istarted building a axle skid tonight. the bottom of the ford 8.8 has a huge lip under it and inside had pockets that i couldnt shave too much becaus i didnt want to get in there so i started to build this, at first i used 1/2in plate then the rest is 3/16 plate that was welded with1/8in 7018 at 120 amps. i only got a litle more than half done so here it is. the first pics are of the lip and other things that hang up on rocks. then the reat are of the building of the skid

GrnTJ 11-05-2008 11:08 PM

Lmao, dang dude, that things nuts! Its a pretty good idea though and Id put my money on it holding up pretty well. I like the philosophy, if you cant shave it down then you might as well build the hell out of it. Looks like welding the tube came out really well too. You chose the right rod for sure. Great job man, snap some more pics when you done with it.

64panhead 11-08-2008 05:52 PM

i only had part of the tube done at that point i got them all welded up now and i was finishing the skid but right now im letting it cool down and i will have pics later tonight

jpdocdave 11-08-2008 08:49 PM

i'm curious how those tube welds hold, i thought you had to heli arc those.

64panhead 11-08-2008 10:40 PM

i dont think it will be an issue:cool:

64panhead 11-09-2008 09:22 PM

now that i have the bottom done i will get the old dana 35 out from its hiding place under my jeep and start making the jig, in order to get building the link mounts. sorry that ive been going slow at this but family first i only have time to work on it at night. here is what the skid turned out like

here it is before any grinding or blending

then after blending with a little paint to keep surface rust away

Rawkon 11-11-2008 10:05 AM

looks great man, I highly recomend buying a pint of POR 15 to coat that axle with.

1BLKJP 11-11-2008 11:25 PM


Originally Posted by jpdocdave (Post 280937)
i'm curious how those tube welds hold, i thought you had to heli arc those.

Welding cast to steel isn't that hard. You just have to make sure that you get both materials to the same temperature before and after you weld them and then let them cool naturally. An oven is best for this, but using a torch on both surfaces to heat them up before and after the weld will help the actual weld bond better. It's really getting all of the moisture out of the cast that is the important part of this process.

Tacking the tubes on an 8.8 is always a good idea. I have have actually seen a tube spin in one.

64panhead 11-12-2008 05:31 AM

i did use a torch on it to pre heat the assembly before i welded it:D

64panhead 11-21-2008 09:29 PM

its been real cold up here in almost friggin canada:banghead: but with the help of a fuel oil space heater and a propane powered jet heater, i was able to get the old axle out of my jeep you know its funny how easily a jeep will sh!t a dana 35 out the back. it took exactly an hout to get it out. here is a couple of pics.

anyone need a rustys offroad skid for a dana 35

64panhead 11-28-2008 10:20 PM

tonight i got the old dana 35 on the bench to start building the jig to relocate the link brackets to the ford 8.8. i made the jig out of 1/2in rebar and 5/16in rod with pipe for the link locations. the first pic is a little fuzzy but it overall turned out good. let me know what you think

flattietj 12-01-2008 10:42 AM

i posted up a long time ago on this about the disc brake rearends and i probably agree wiht you on the discs since the 8.8 disc brakes are a joke.....the pads are only like 1.5"s wide....ive had much better braking out of my ford 9" drums

64panhead 12-07-2008 06:08 PM

update on my project. the other day i got all measurements and pinion angle. so i cut off all the brackets and moved my jig over to my new axle centered it and started on the shock mounts. let me tell you that the d35 is a tiny thing compared to the 8.8, it took some fitting back and forth between the torches and grinder to get them square but in the end the bolts slide threw like nothing now. here are a couple of pics of the brackets and the jig. the right side is done but then i ran out of wire and couldnt finnish the left. funny thing is i have a new 10lb spool in the box at my dads shop.

GrnTJ 12-07-2008 07:09 PM

Keep it up dude, this thing is gonna be awesome when your done! Nice work with the jig, gonna make things way easier on you for bracket placement. Hope you get that other spool of wire soon so you can get it finished and provide more pics:D

64panhead 12-07-2008 08:03 PM

i will pick up the new spool tomorrow along with an exchange on the oxygen tank, then i will get working on the lower link brackets:D

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