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Thread: 8.8 axle build

  1. #1
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    8.8 axle build

    I was still using my ticking time bomb, Dana 35. I have 35's with the dana 35 (307 gears) and haven't had serious problems(I had to weld the spider gears with an onboard welder, at Camp NL, so I could tow my trailer home). Having a broke axle on the trail is never fun. Seen it happen to many times, so its my time to upgrade.
    I picked up a 8.8 axle out of a 2001 ford exploder for $200 at a local scrap yard. It came with everything on it. Aprrox 135000 Kms, 4:10 gears, no locker and 10 LBS of rust.
    I stripped it down bare and got the center section ready to weld. I am using the mig pac 180 with gas so before welding anything I added heat. I tacked it all around then did 1" stich welds.
    Attached Thumbnails Attached Thumbnails DSC04050.jpg   DSC04051.jpg   DSC04053.jpg   DSC04071.jpg   DSC04073.jpg  

    Last edited by WiGiT; 10-31-2009 at 11:58 AM.

  2. #2
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    Good deal ,
    Member of LAJOC. www.londonjeepclub.org

  3. #3
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    ^ X2... even got the end of the DS.
    My latest project... Collection of Parts

    Other stuff... Building a doubler, D300 Flip kit

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  4. #4
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    looking to do the same in the furure....will keep an eye on ur build...
    P.S.S I love the shot of your bullie in the background of pic #1 !!

    heres a shot of mine...
    Last edited by KrAzYkRaZ; 10-31-2009 at 01:55 PM.

  5. #5
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    Thanx. Unfortunatly Moose passed away in july, sure do miss him buggin' me in the garage. He was 9.5 years old.
    I purchaced the M.O.R.E brackets, e-brake cables and flange for DS (bought the flange before axle). I used a floor creeper with 3/16 plate to make a movable jig. welded a stand to set pinnion angle. Then measured all the brakcets for there centres and angles off of the Dana35. Mounted the new brackets with a strong couple of tacks. I removed the old and wheeled in the new. Everything was good so I took it back out and welded it up. The paint I used is POR 15 and Caliper paint blue. Everything was wire wheeled and/or sand blasted. The calipers were not seized and work fine but I had to buy new rotors and e-brake hardwear. I used 2 pass side flex lines and ran new steel lines. The 8.8 axle is 1 1/4" narrower so I used wheel spacers and now its 1 1/4" wider than the 35. I will be getting a heavier diff cover later.
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  6. #6
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    Nice looking axle.... should work real good for you. I can't wait to finish mine now.

    are you planning on locking it?

  7. #7
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    I did have a aussie locker, rachet type, in it. Hated it, so for now I run open. I have ran open for as long as I've been wheeln' and do very well. I have to save up and get a selectable locker. The biggest gain I am going for is the 4:10 gears. So I had a dana 30 out of a 4cyl Tj to mach the front gearing but the guy took it out one more time and blew it up. With one week left before going to Trailfest I needed to re-gear the front, add a slip yoke eliminator kit and a CV driveshaft. I called Jim at Rock Spider and he had everthing in stock and got a custom drive shaft made in two days, not bad!
    The SYE kit is from Advanced Adapters. It took one evening to remove the t-case, install the kit and put the t-case back in. The drive shaft is 100% greasable and the angles are in spec.
    The regearing portion took me three evenings to get it right. This was my first time attempt changing a set myself. I did my research and took Jimmys advice and took my time. I must of put the carrier and pinnion in over a dozen times before I got it right.
    While it was on the hoist I found the front coil had split lenght wise, I had newer springs for a ZJ with the same lift. They are 1.5" longer, witch is fine cause the rear is sitting high due to the larger dia axle tube. Also stole the track bar from the ZJ lift.
    Everything ending up working great. No howelling from the gears, no vibrations, and I can use fith gear down the highway, actually I HAVE to use fith gear down the highway. 4low is now good and low!
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  8. #8
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    looks good.
    '99 superduty, 7.3L diesel. 4x4, ex cab short box. edge evolution programmer. straight pipe, torque converter lock up switch. single 7" stack, built tranny with some billet bits inside, 7' trac bars, pyro,boost an tranny guages. 4" lift in the front 5" rear. 305 70 16 mickey thompson baja mtz's on m/t classic 2's. now with dana 60 front, 10.5" rear 3:7.3's. 5" airlift bags in the rear.

    2002 polaris pro-x 440 with 2004 600 motor. walker evans remotes all the way around.

  9. #9
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    i like that blue
    lookin' good!

  10. #10
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    If that was 10lbs of rust on it, I'd hate to add up the weight of rust on my D60!!!!
    90 YJ. 4link F/R, 16" SAW Airshocks, 32bolt Beadlocks, D60/14bolt, Full Hydro/Hydroboost L67 3.8SC 700r4 NP231/D300
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    I prefer to build it and not buy it, you see it, I probably made it.

  11. #11
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    The blue paint is actually caliper paint. I find it holds up well. It dosen't have a great finish but after one coat of mud any paint looks the same.
    10lbs of rust, that was just a sarcastic guess. I'm sure it was closer to 2 or 3lbs. I am always impressed how well a junkyard part can clean up!
    Good luck with your d60 built up You probably will get 10lbs of rust off of it.
    We have put about 3000 kms on all the work I did and havn't had any problems. I think its time for some steering upgrades tho! My wife wheels' the TJ (it is hers and all) and got stuck in a deep hole. She got pulled out backwards looked at it again and went a little faster. After a solid min of roostertails she muscled it out. I love my wife, she keeps me busy
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  12. #12
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    See you in the spring for some runs. Give me a shout if you need a hand. Nice work once again on the jeep.

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