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Thread: D35 axle swap for YJ

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    USNA 2013 farmboyqb's Avatar
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    Default D35 axle swap for YJ

    Ive been hearing a bunch of guys talk about the D35 being a pretty crummy axle for wheeling. Ive also heard that swapping it with a donor D44 or ford 8.8 is a possibility but it would require alot of work. Basically id like to know what it would take to upgrade my rear end to a D44 or better
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    Land Squid Jeffb_79's Avatar
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    You can get a ford 8.8 with 4.10 gears and disc brakes for under $500.
    Add in the cost of brackets to make it compatible with a tj.
    Cut the old crap off your self and clean it up.
    Take it to someone to have them weld the new brackets on.
    I'd say around $1k.
    I would go 8.8 over a D44. A D44 is going to have a different lug pattern than your stock axles, so you'd need an adaptor. And the 8.8 is stronger.
    There was a vendor on ebay that builds 8.8s to your spec. I want to say you could get an 8.8 with gears of your choice, tj brackets installed and a locker for about $1600.

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    Zombie Hunter DirtWarrior97's Avatar
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    He's putting it on a YJ....but it would still require cutting off the spring perches and welding up new ones...
    Prepare for zombies. That way you'll be ready for anything.

    '97 TJ Sport 5" Teraflex LCG Max, 1" BL, 1" MML, Mopar JK Rubicon Axles, 35" BFGoodrich Mud Terrain KM2's, Custom Rock Sliders, Custom Stinger Bumper, 8000 lb winch, Poison Spyder Tube Fenders, Teraflex skid plates under steering box, oil pan, transfer case and gas tank.

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    Land Squid Jeffb_79's Avatar
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    Quote Originally Posted by DirtWarrior97 View Post
    He's putting it on a YJ....but it would still require cutting off the spring perches and welding up new ones...

    Eh... same difference. Won't have to worry about spring perches, but will have to have the shock mounts moved.

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    USNA 2013 farmboyqb's Avatar
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    So the shock mounts on the axle or the shock mounts on the frame itself will have to be moved?

    What year rear end should I be looking for and what type of gearing. I believe the stock gearing is 3.73 but i could be wrong.
    Last edited by farmboyqb; 10-02-2009 at 23:06.
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    Land Squid Jeffb_79's Avatar
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    1995-2001 ford explore came with disc brakes, 31 spline shafts, either 3.73 or 4.10, posi trac. They are c-clip axles just like the d35... probably not a big deal unless you're running larger than 36" tires. Axle tubes could use a weld bead where they meet the differential.

    http://www.jedi.com/obiwan/jeep/ford88.html
    http://www.cherokeeforum.com/f30/for...wap-info-3847/

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    Zombie Slayer... JoeySnow70's Avatar
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    Quote Originally Posted by Jeffb_79 View Post
    1995-2001 ford explore came with disc brakes, 31 spline shafts, either 3.73 or 4.10, posi trac. They are c-clip axles just like the d35... probably not a big deal unless you're running larger than 36" tires. Axle tubes could use a weld bead where they meet the differential.

    http://www.jedi.com/obiwan/jeep/ford88.html
    http://www.cherokeeforum.com/f30/ford-8-8-swap-info-3847/
    Also Mercury Mountaineer's and Mazda Navajo's, of the same years stated...
    Obiwan's page is great for a YJ set up....
    Last edited by JoeySnow70; 10-03-2009 at 10:33. Reason: I cant spell worth of $h!t

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    Junior Member chucknes's Avatar
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    Thumbs up lots of good info, no speculation!

    hey bro, i think that you should have as much good info as is possible, so being the good Samaritan that i am, i have done some research. here is the list of links that i came up with...

    http://www.therangerstation.com/tech_library/index.php

    http://www.jeepforum.com/forum/f12/f...inally-636291/

    this is a good write up on the swap...

    http://www.jedi.com/obiwan/jeep/ford88.html

    the following is a short answer to a question on www.jeepforum.com it is to the point and informative.

    "The swap in is as simple as doing the 8.8 swap. You can use the same bracket kits they sell for the 8.8. The early bronco axles are a bit shorter than even the 8.8 axles. The lug pattern will be 5 on 5.5 but can be converted with a set of spacers that make the width just right. As for strength, after market and the plethora of second hand parts, the 9" gets the nod. Go with the big bearing housing. If its not 31 spline thats easy to remedy but getting shafts for 31 spline with the small bearing is pretty much impossible. Even on the custom front.

    Depending on your goals, 28 spline is still not a bad upgrade but make sure you have the option to upgrade to 31 splines etc by going with the big bearing housing. Course you can weld big bearing ends on the housing. Ahh the 9" ford, endless possibilities."


    MTF


    another answer to another similar ?

    "you are touching on the biggest issue with the STOCK 8.8 swap. this is an absolutely awesome swap if you intend to stay with 35" tires. after that and you jump into a world of other issues namely the front axle assembly. there is no good front axle assembly swaps that will match the STOCK width and bolt pattern that an 8.8 have. what makes it desirable for cheap also becomes its Achilles heal when going bigger.
    i say STOCK because now there are upgrades available for the 8.8 that make it more versatile. if i were going with an 8.8 swap i would "build" it outright with superiors kit to add width and change the bolt pattern to 5 on 5.5. i would then be able to use a narrowed dana 44 from an old ford pickup up front. a 44 and 8.8 would make a nice combination. and you could probably get away with a bit more tire.
    another interesting avenue is grabbing a set of mopar jk rubicon dana 44 axle assemblies. they are already 62" or so wide, have selectable lockers and aftermarket support for a pattern change to 5 on 5.5 and manual locking hubs. this might just be the route for my next project just to do something alittle different.
    many people are going to tell you to simply put some chromo shafts in the 30 and be done with it. i personally decided not to put any money into the 30 knowing i was going bigger. this is the issue you will want to ponder. if you have any inkling in going bigger, not necessarily in tire size but in terms of durability, then i say hunt for the swap. if you wheel close to home, by yourself, and in a slow manner then fine live with the 30. if you wheel a thousand or so miles from home or anything for that matter, always have people with you, and like to get on it then swap. the piece of mind is a nice thing.


    and another...

    "The 8.8 is stronger than a 44, and about the same as a 9 inch, although the 9 inch is a 3rd member, a more desireable feature imo.
    The 8.8 width is a nice feature, about the same as stock, not to mention disc brakes.

    From another forum...
    The axle shaft strength tested by Warn Ind:
    F8.8= 6,500 (lb. ft.)
    D44= 4,600-5,000 (lb. ft.)
    D35C= 4,000-4,300 (lb. ft.)
    -------------------------------
    COT: Continuous output torque rating
    MOT: Maximum output torque rating

    (Numbers from January edition of Fourwheeler, page 60.)
    Dana 35 rear axle COT: 870 MOT: 3480
    Dana 44 rear axle COT: 1100 MOT: 4460
    Ford 8.8 28spline COT: 1250 MOT: 4600
    Ford 8.8 31spline COT: 1360 MOT: 5100
    Dana60 semifloat COT: 1500 MOT: 5500]


    I run a Super 30 in my front. Strong, and a good match for the 8.8 I have, bolt pattern wise."

    this is a good list of things that should answer some of your questions! again, an answer to a question on another forum.

    8.8 INFORMATION

    Here we go with some parts and info I have been gathering for the 8.8 swap.... Some replacemnt parts/adapter style parts....

    -------------------------------------------------

    Replacement brake pads (P/N 6674, AutoZone) =$39.99

    Replacement Calipers (P/N's C576 &C577, AutoZone)

    Replacement Guide pins (2 - H15068, AutoZone)

    Replacement Banjo bolts (Ford P/N 385116-S2)

    Replacement Hoses (2 - NAPA P/N 380376 & 380528 )=$51.79 E-brake cables (Mopar P/N's 52008904 & 05)

    Replacement "T" Hose (P/N 380889, NAPA)

    Replacement 2 - Hard Brake Lines(NAPA P/N 813-1208 & 813-1204 )=$6.73

    Yoke Adapter (Spicer P/N 2-2-1379, NAPA) I SUSPECT THIS IS CHEAPER THAN @ THE ONLINE SOURCES....

    You can also get the 1310 ujoint yoke for the ranger 8.8 (bolt to the explorer 8.8) from a ford dealership for around $28. I had a friend check on this yesterday.

    There is also a 1310/1330 combo ujoint floating around out there. Neapco # 1-0134. It is available from rubicon outfitters for $21.95 RE1823
    (does anyone happen to have a napa part number for this?)

    Replacement Yoke bolts (Ford P/N N800594-S100) I belieft these are 12mm 1.5" grade 5 bolts..... not certain though

    Now I figure that the yoke adapter from ford and napa are probably the same part number and will make the 8.8 as close to bolt in as it can get.

    The explorer 8.8 will have the 1330 ujoint yoke on it. same as on the cryco 8.25 rear found on the xj's. You could use the 1310/1330 adapter joint to just mate the factory yj shaft to the 8.8 then....

    Here is stuff I found in the google cashe of the tj section of JU.

    Ford 8.8 specs:
    Weight (complete assembly w/ brakes etc.): 174 lb.
    Drivers side Ford brake hose #: F5TZ-2282-A
    Passenger side brake hose #: XL2Z-2282-AA
    Bolt size (U-joint flange to yoke) is: 12 x 1.75 x 30 mm

    Axle shaft Strength and output torque rating by Warn and 4 Wheeler
    (thanks joe and Chile99.)

    The axle shaft strength (tested by Warn Ind.) is as follows:
    F8.8= 6,500 (lb. ft.)
    D44= 4,600-5,000 (lb. ft.)
    D35C= 4,000-4,300 (lb. ft.)

    COT: Continuous output torque rating
    MOT: Maximum output torque rating
    Numbers from January edition of Fourwheeler, page 60.
    Dana 35 rear axle COT: 870 MOT: 3480
    Dana 44 rear axle COT: 1100 MOT: 4460
    Ford 8.8 28spline COT: 1250 MOT: 4600
    Ford 8.8 31spline COT: 1360 MOT: 5100
    Dana60 semifloat COT: 1500 MOT: 5500

    Measurements:
    O.D. of tubes: 3.250".
    Tube thickness: .250" (some are .188”!)
    Ring gear diameter: 8.800".
    Ring gear bolts: 7/16" dia. (qty. 10).
    Pinion diameter/splines: 1.625 / 30.
    Axle shaft/splines: 1.320 / 31.
    Rotor thickness (where it mounts to axle is .250").
    Overall width* 59.625" (the F8.8 is .950" narrower then a TJ Dana 35).
    Hole diameter for ABS sensor in top of housing: .811".
    Centerline of housing to C/L of pinion difference is 3.875" toward the P/S.
    Pinion offset: P/S to C/L of Pinion, 27-3/4" (no rotor on axle), D/S to C/L of Pinion, 31-5/8" (no rotor on axle). (this measurement is 2.5" more offset to the P/S then a TJ Dana 35).

    *Explorer & Mountaineer.
    (The F-150 8.8 is drum brake and width WMS to WMS is 65.5”.)


    Specs:
    Code Capacity Ratio
    43 Open 3200 3.08
    41 Open 3200 3.27
    42 Open 4.10
    46 Open 3.73
    45 Open 3200 3.55
    D4 Limited Slip 3200 3.73
    D2 Limited Slip 4.10
    L73 Limited Slip 3.73
    L - Limited Slip Differential
    C - Conventional Differential

    Thanks Chris Overacker for the specs and measurements! see his website link below.

    How many splines are the axle shafts? Standard axle shaft for drivers side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 30-1/2 inch length - 5 X 4.5 inch lug pattern.

    Standard axle shaft for passenger side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 27-5/8 inch length - 5 X 4.5 inch lug pattern

    Can I get 35 spline shafts? Yes

    Do I need a slip yoke eliminator? In my opinion, yes

    Can I use my drive shaft that I bought for my SYE/Dana 35 set-up? Yes

    Is the 8.8 narrower than a Dana 35? Yes but not enough to make a difference when running most aftermarket wheels.1.5" shorter or so. It doesn't matter unless you try running stock rims w/12.5 or wider tires.

    Are the 8.8 shafts stronger than Dana 44 shafts? Yes, also the bearings, pinion and ring gear are also much larger.

    Will I need that brake proportioning valve "thingey" from a Rubicon? Maybe

    Does the 8.8 offer more ground clearance over the Dana 35 and 44? Not under the differential but the bigger axle tubes lift the rig about 5/8 ". (soa rigs here guys... opposite on sua rigs...)

    Is there welding involved? Yes, but the new brackets you put on are much stronger than stock Dana’s.

    Where do I get brackets? TeraFlex, M.O.R.E., Rubicon Express (to name a few).

    Should I weld the axle tubes to the cast housing? I would if it had been salvaged from a wrecked rig. If it is new on a crate (in my opinion) don’t bother.

    Will my stock sway bar work? Yes, with a minor modification to a pinion gusset.

    Do all 8.8s come with a limited slip? No, read the tag on the housing or remove the cover.

    Where is the gear break for lockers? There is no break. Same locker for 3.73 to 6.14

    Do I need a notched cross pin? Yes for 4.56-5.13 to clear ring gear (unsure about lower gears)

    What year ford explorers do I look for as a donor for 31 spline and disc brakes? 1995 to 2001.

    What is so great about 8.8? Parts are everywhere, as in axle shafts, covers, brake parts etc..

    What's not so great about the 8.8? Weak stock carrier, replace with a carrier type locker like ARB or Detroit (not a lunch box type) this will cure the problem.

    Spun axle tubes: Simply weld the tubes into the diff housing before they spin. You are welding to cast steel so now would be the time to ask for a professional's opinion. I have heard of guys tossing the works in a oven before welding, some just go at it cold. Both say their way is right.

    Thin stock diff cover: Get some armor.

    (my axle was new surplus and had not been in a collision, i know exactly where it has been from mile one and it is not welded. I dont believe my wheeling style will cause me problems, however i do keep a close eye on the plug welds.)

    What kind of locker can I get? Anything like a spool, mini spool, Detroit, ARB, Eaton limited slip….

    What is the bolt pattern? 5 on 4.5” just like stock TJ/YJ wheels.

    Will my Jeep lug nuts fit the 8.8? In most cases, yes.

    What do I do with the speed sensor? leave it in place.

    Where to buy? Car-part.com www.ok4wd.com wallysheata, Ariel Performance, www.alljeep.com http://www.rockequipment.com to name a few.

    How much do they cost? Free to $1500.00 but you can find them new for around $500.00 in their stock form complete disc to disc.

    What do I need for a swap into a tj?
    Here are some things I used:

    TeraFlex Bracket kit $200.00
    ARB $630.00
    U.S. Gears 4.56 $185.96
    Master install kit (Timken) $89.00
    Crane diff cover $190.00
    Napa brake line kit P/N 380528 $17.49 (x2)
    T-hose NAPA P/N 380889 $29.99
    ZJ E-brake cables Mopar P/N 52008904 & 52008905 $23.00 (x2) (for TJs only)
    Driveshaft adapter: Spicer 2-2-1379 $32.86 there is more information in the later pages of this thread about these adapters. i will put the info here soon
    Flange bolts Ford P/N N800594-S100 $1.29 (x4)
    '03 TJ Rubicon (w/disc) proportioning valve P/N 5083808AA $74.00
    3/16" hard brake line 60" (40"?) & 18" $5.00

    Here are some locker prices Joe found.
    $690.48 ARB SELECTABLE AIR LOCKER
    $342.69 AUBURN GEAR - HIGH PERFORMANCE LIMITED-SLIP DIFFERENTIAL
    $424.22 AUBURN GEAR - PRO SERIES LIMITED-SLIP DIFFERENTIAL
    $535.72 DETROIT LOCKER
    $229.59 E-Z LOCKER - FITS IN FACTORY NON-POSI CASE
    $641.96 EATON - ELOCKER SELECTABLE LOCKING DIFFERENTIAL
    $388.20 EATON - POSI LIMITED-SLIP DIFFERENTIAL
    $209.04 FULL SPOOL - 31 SPLINE - STEEL
    $118.46 MINI SPOOL - 31 SPLINE - C-CLIP COMPATIBLE - STEEL
    $47.04 MODIFIED CROSS SHAFT
    $160.20 OPEN DIFFERENTIAL BARECASE
    $188.14 OPEN DIFFERENTIAL BARECASE
    $348.40 ORIGINAL STYLE POSI - COMPLETE
    $49.83 POSI CLUTCH PACK KIT - FACTORY/FMS/FRP POSI
    $261.52 POWERTRAX - LOCK-RIGHT LOCKER - FITS IN FACTORY NON-POSI CASE
    $95.46 SPIDER GEAR KIT - OPEN 87 & LATER, 31 SPLINE
    $381.94 TRUTRAC LIMITED-SLIP

    Helpful sites:
    http://www.stu-offroad.com/axle/8.8axle/8.8axle-1.htm Stu Olson's site
    http://home.earthlink.net/~jetmanjay/id6.html Dome & Detour
    http://www.geocities.com/yj3qtr_ton/88swap.html
    http://www.dpgoffroad.com/tech/8.8.htm
    http://www.code4x4.com/projects/axle_88/axle_88.html Chris Overacker's site
    http://www.macamar.com/sitefiles/fo...ap/AxleSwap.htm Stormtrooper
    http://www.4x4wire.com/jeep/tech/axle/

    Ranger Station pages here. Thanks Dan-H:
    http://www.therangerstation.com/tech_library/Axles.html
    http://www.therangerstation.com/tec...xplorer8_8.html

    YJ & XJ STUFF:

    From M.O.R.E.
    -XJ Installation Kit P/N 98600 84-2001 XJ $165.00
    -XJ E-Brake Cable Kit P/N EB3 Disc Brake F8.8 Only $118.00
    -Special Yoke P/N 221379 F8.8 to 1310 U-Joint $40.00

    From Dealership:
    -Mopar spring perches $12.00
    -Tabs for shock mounts $5.00
    -ZJ ebrake cables from the dealer (for XJ install) $65.00
    -Flange from spicer dealer $30 (have seen this go from $20-$50)

    well i think that should be enough to get you started. i really like doing research, so that was fun. let me know if you need anything else, or if you feel like that was harassment. i know its a ton of info, but i think you were looking to make an educated decision. thats really the best i can do at the time though, (it is 0400 here in germany right now!)

    any how, good night, and good luck!
    stock unlimited... building parts bin... looking for a house
    e mail: [email protected]

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    Member reservoirdogg26's Avatar
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    yeah...what chucknes said
    " if you can read this, thank a teacher.
    If you are reading it in English, thank a Soldier"

    I READ TODD DID

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    USNA 2013 farmboyqb's Avatar
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    So heres another question. If I go with a 8.8, would i want to also do a spring over conversion at the same time. And would that mean i would have to reainstall the stock springs because i am running 4" lift srings
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