The DANA 60 upgrade

[XJ4IV]

ok JUST as a heads up this build MIGHT take a little bit BUT im on my way and I already made the first big investment towards doing it...
Check out what I scrounged up from CL for $240
http://i372.photobucket.com/albums/oo167/seivey/2010-12-20142832.jpg

[Mudderoy]

ok JUST as a heads up this build MIGHT take a little bit BUT im on my way and I already made the first big investment towards doing it...
Check out what I scrounged up from CL for $240
http://i372.photobucket.com/albums/oo167/seivey/2010-12-20142832.jpg

Ok what are they, specifically the size?

[XJ4IV]

well they are 17x8.5 and whats missing is THIS
http://i372.photobucket.com/albums/oo167/seivey/2010-12-20142815.jpg
I know I know I know but SO WHAT they look awesome on jeeps with full width axles
http://i29.tinypic.com/9itxrq.jpg

[XJ4IV]

I already have the cash to get the axles I just dont have the TIME to get out the the JY... PLUS if I wait til new years day I can take advantage of the 1/2 off deals at pick a part... I called them yesterday and they said any axles 3/4 and up are 125 a piece ... so on that day I can score them BOTH for that much... I hope to find a dually 4x4 with a tow pack so I can get the 4:56 gears... GO FORD SUPER DUTY!!!

[ironmanandy]

Hey man I just wanted to let you know that the super duty 60s use a different bolt pattern and almost all brake set ups require a 20" rim.

They use an 8x170mm bolt pattern and tend to be around 72" wide.

Finding wheels and tires that will fit the axle are $$$$$$$$$$$$$
I had one that I just gave away for 500.00 because of how much work it was going to take to get before i could use it.

There is a company called EMS that can put a new lug pattern in your hubs and machine the knuckles so that you can run high steer

A

[XJ4IV]

Ive done LOTS of research thus far on the setups and found that mid 90's axles from a f250 should be the same pattern the ONLY modification you need to make is to remove a small lip on the inside of the hummer wheel... like 1/8 of material and since its aluminum its pretty easy... thats what I work with every day ! If not Ill make a lug pattern template to take with me to the JY ...Im pretty excited

[msmoorenburg]

Ive done LOTS of research thus far on the setups and found that mid 90's axles from a f250 should be the same pattern the ONLY modification you need to make is to remove a small lip on the inside of the hummer wheel... like 1/8 of material and since its aluminum its pretty easy... thats what I work with every day ! If not Ill make a lug pattern template to take with me to the JY ...Im pretty excited

I had a place in houston machine it out on a set of rims for $100

[Mudderoy]

I had a place in houston machine it out on a set of rims for $100

That's the way to do it right. :thumbsup:

[XJ4IV]

wait WHAT did they do exactly?

[msmoorenburg]

wait WHAT did they do exactly?


they machined the to be hub centric

[XJ4IV]

machined the wheel? and what exactly is hub centric?

[bigjim350]

Im sure he means they machined the center hole out larger, so that with would fit on something with a larger hub. Hub centeric means the hub centers the wheels, not the lug nuts

[cantab27]

hey Scott will watch this thread with interest ,,, but to start with ,what are the Dana 60 out of ,,,, cheers

[GT MOTORSPORTS]

Im with Iron Man. In 96' fford changed the 250 and 350 to the 8 170mm pattern. I had a set of wheels I was trying to sale for a friend that came off his 96' f250 and every one wanted them since they were aluminum but they wont fir the chevy/dodge axles. Good luck on your JY shopping spree..if it was 26* with a foot of snow on the ground Id hit up our pull and pay yard...damn Ohio weather..lol

[modestmar00xj]

nice build man! cant wait to see it!

[XJ4IV]

So I just ned to find a 95 then right? lol

[Mudderoy]

You can listen to Scott "XJ4IV" talk about his DANA 60 project plans on the December 22nd xjtalk "talk" show podcast!!

http://www.xjtalk.com/podcasts.php :thumbsup:

[ironmanandy]

Just make sure the axle you find is a kingpin 60. Only the ball joint 60 has the metric lug pattern. Setting up your high steer will be much easier as well.

These axles are quite hard to find for under a grand. If someone knew of one in a pull a part it would be gone in a heartbeat because most everyone knows they can turn around and sell it within a few days and make a $$$ every time!

From watching your 4 wheeling videos and from what i can tell from your pictures, you would be just fine finding an 8 lug hp 44 HD/D 60 rear combo. These are much more prevalent and cost effective. These showed up in ford trucks from 73-79 and some 90s models as well. They were also in some j trucks. I am not sure about the 80s because well.... The 80s just sucked for the automotive world. The only cool thing I can think of was the lotus esprit (with Julia Roberts), the DeLorian, (with or without Micheal J fox), And AMC downsizing its outdated and heavy grand wagoneer into the beloved XJ that brings us all together.:-) Some folks say The XJ saved AMC long enough for Chrysler to buy it. I think Chrysler is stupid for killing it! Anywhoo back to the 60 talk.

If you are worried about shaft strength you can get into alloy shafts and joints for less than most junkyards want for a real KP60.

Jana also makes an upgrade so you can run dana 50 R&P in a dana 44.

I just sold my Front 60 because I am going to be able to build an indestructible 44 front with 35 spline shafts for cheaper than I can get a 60 under my race jeep.

Good luck with this. Every time I hear someone mentioning putting a 60 under an XJ, I chuckle because i know its always a feat no matter who they are or how experienced.

A

[4.3LXJ]

I agree with Andy. You can build a 44 that will match a 60 for strength and surpass it in axle strength.

These are spendy, but well worth it because even a 60 axle will fail in a sharp turn. These won't.

https://www.rcvperformance.com/store/catalog/index.php?cPath=53&osCsid=1305b12b943006be1c42f20f14737d0c

[XJ4IV]

... I know your all gonna laugh but What is the kingpin setup?, and also andy those wheelin vids are me toned WAY down im into rock crawlin like the rubicon... anyhow that ALL being said I have seriously been debating on the d44 route as well but what vehicles can I find the d44 in 8 lug that matches these H2 wheels and is full width... doesnt HAVE to be 65 inches but pretty dang close!
also where can I find the driver side front axle? I dont mind going to a slightly smaller axle as I HAVE had great luck with my 30/35 setup I just dont wanna break and not be able to wheel for the rest of the day OR weekend!

[ironmanandy]

Any ford truck dana 44 from 73 up will do.

You can buy a hub/rotor combo with the 8 lug on it from any parts store.

A kingpin vs. ball joint is the style of swivel that allows the axle to steer. The kingpin is more desirable for strength and you can buy high steer arms that bolt right to the top of it.

A ball joint 60 is essentially a dana 30 on Steroids.
Dont get me wrong if I had the time and money I would run the ball joint 249 model D60 I sold any day over any other. It just involved way too much modification.

Scott, If i was your professor I would require this reading material before you go any farther. This has excellent info on what you are getting into.

Read all sections, you will be tested.

http://77cj.littlekeylime.com/web_rs44.html

Merry christmas.
Andy

[XJ4IV]

Soooooo I think I may have found a Diamond in the rough... I POSSIBLY put my eyes on a 95 model f250 gasoline that had a sterling 10.25 in it that was running the 8 lug pattern I needed... I was able to remove a centercap from a 2500 HD chevy with 8 lugs and I took it over to the sterling rearend and the cap holes lined up perfectly to the lug studs so either this one was modified or... I just got lucky... can anyone chime in and tell me a reason I shouldnt go with the sterling and still get a 60? Im still having trouble locating a front axle though... I supose I could go with a D44 front axle kinda like the 35/30 combo only its bigger brother.

[4.3LXJ]

Soooooo I think I may have found a Diamond in the rough... I POSSIBLY put my eyes on a 95 model f250 gasoline that had a sterling 10.25 in it that was running the 8 lug pattern I needed... I was able to remove a centercap from a 2500 HD chevy with 8 lugs and I took it over to the sterling rearend and the cap holes lined up perfectly to the lug studs so either this one was modified or... I just got lucky... can anyone chime in and tell me a reason I shouldnt go with the sterling and still get a 60? Im still having trouble locating a front axle though... I supose I could go with a D44 front axle kinda like the 35/30 combo only its bigger brother.

You might want to visit a website like Randy's Ring and Pinion and compare what gear ratios and lockers are available for the Sterling and D44 and D60. Things like this can make or break a project.

[ironmanandy]

you will find tough shafts in the sterling but the housing is paper thin.
You will also find a good range of Ring and pinions for it.
Not very good in the rocks. well if you hit one that is.
If I were you I would keep looking. I have made the mistake of trying to rush into this.

For rear axles look at old work vans etc alot of those come with dana 60s. Another diamond is a dana 70 It is very identifiable by the 3.5" acle tubes and the 70 very clear on the housing. They made some with a perfectly smooth housing that glides over obstacles.
Most of these came in single wheel f250s and up. They have 35 spline shafts always and are super tough. The Dana 70s usually come with 4.10 gears and a powerlock rear diff.

with a good disk brake conversion its a sweet setup.

When you get to the junk yard just start pulling shafts off the rear ends and look for 35 splines. If you don't have 35 don't waste your time.

A

[XJ4IV]

... sadly im really just gonna weld the rear up... Im poor guy and cannot swing a 800 dollar locker but as far as the two axles I found today Im pretty happy but as for rocks yeah Im kinda leary about that, ive heard that the sterling offers better clearance though over the 60

[ironmanandy]

based on your expense comment in chat.
If you want to run a 44 or 60 on an XJ you will have to get all of the brackets, and weld them on. That normally runs around $200.00 for the crap ones.

You will need a real steering setup.
expect to budget around $500.00 for the components not including the actual rods.
budget another $1-200 for tubing inserts, etc. That is a liberal number

Track bar will need to match the angle of the drag link. You will need a straight track bar.
$100.00 ish

you will need to make the brake equipment match up including proportioning valve and proper master.

at least 200.00

I would budget 1200+or - to get a front axle in that XJ

This is realistic. hope this helps
A

[XJ4IV]

wow.... soooo your trackbar setup will not work with this axle? DAMN I was SOOOOO pumped up

[ironmanandy]

just the track bar, your bracket on the frame is fine

[Mudderoy]

It's great you're going a different direction on this Scott. Looks of good and interesting information being shared. Love it.

[4.3LXJ]

Scott, you can shave that price to 10 - 20 percent of that figure IF you can fabricate. If you have long arms, or get some of Andy's, you can make your own mounting tabs to fit, track bar brackets etc. I am cheap, so that is what I do. If I didn't, my build would never have happened. I would still be paying off a winch bumper.

[Mudderoy]

http://www.youtube.com/watch?v=I4jHOkcJn4c

[XJ4IV]

http://www.youtube.com/watch?v=i4jhokcjn4c
i want! Me likeeeeey

[TeXJ]

how come thats a dead link to me when i click on it in the quote?

edit: just had to wait for muddy's post to load...

[4x4Dalton]

I'm gonna keep my eyes on this thread. Later on down the road I'm thinkin of doing a whole front and rear swap. But thats on down the road a ways. With all this info being posted I'm sure it will be a great rig once yer done bro. Cant wait to see the final results.

[XJ4IV]

its a great rig NOW I just want Insurance while on the trails... I currently run a dana 30 front and 35 rear on 33's and I wheel fairly good and pretty hard considering whats under my jeep but Ive had a few buds break their axles on the first trail of the day and ruin the WHOLE weekend and I DAMN sure dont want that to happen to me! sooo when its DONE it will be AWESOME!!!

[4.3LXJ]

Unless you are going to use some tires over 35", might I suggest a D44 with 35 spline alloy axles? That will cost more than a bare bones D60, but it will be a bolt in and just as strong and not have that large pumpkin. However then you can do the same with the D30 on the axles and have plenty of strength. Personally, I am going for the strong axle shafts and small pumpkins so they don't hang up on everything.

[XJ4IV]

My intentions are to use 37 or 38's... I found a decent deal for 38 inch Maxxis creepy crawlers for 290 each... thats about the vest deal I can locate

[XJ4IV]

I think Im in love with an XJ ...
Hot Springs ORV- Ingrids Revenge - YouTube!

http://www.youtube.com/watch?v=TMOenUF8ZVo

[XJ4IV]

SOOOOOO shopping turned out pretty good today... half off at the local junk yard meant JACK the price list WAY up and then TELL them your getting half off.... I called about three weeks ago and got a price for the dana 60 over the phone of 129 plus a 30 dollar core... well WTF mate... I paid 176 for the rear axle and also scored a set of 4 tires to hold me over for the next few months for 60 bucks... so not TOOOOOO bad but certainly not 1/2 off what Id expected!... heres the rear I got
http://i372.photobucket.com/albums/oo167/seivey/IMG005.jpg
heres what it came out of... POS E350
http://i372.photobucket.com/albums/oo167/seivey/IMG006.jpg
I tried to argue the price of this transfer case but they wouldnt budge... no worries though I know where I can get it and it was already removed so no labor involved
http://i372.photobucket.com/albums/oo167/seivey/IMG007.jpg

[modestmar00xj]

what a great link! i want to swap out my d30/8.25 to d44/8.8 and with reasearch and the info from this link fellin pritty confident! there's just tooo many different d44's! damn! but thanks IRONMANANDY for that link! And 4.3LXJ you crack me up!, " large pumpkin" hahaha

[XJ4IV]

IF you can locate a junkyard like the one I went to today crawl under EVERY XJ and just look... I found like 12 8.25's under newer XJ's and I also found TWO d44's under xj's... I almost scrapped the d60 plan to go this route but... seeing those wide track axles makes me smile!!!

[TeXJ]

Nice find so do u have a front one yet?

[XJ4IV]

no the front one Im SERIOUSLY just gonna have to choke up and pay lots for it I guess! I gotta hit every yard I drive by and have green in hand

[ironmanandy]

Hey man pull those 8 bolts off of that full floater and see how many splines are on that bad boy.
A

[XJ4IV]

I will tear it apart probably later this week... its pretty nasty with grime... whats a full floater mean and whats the benefits of it? also I tried to call you today to check something... I found a 9something f250 4x4... only HD 4x4 at the WHOLE place anyhow it was the one with that faggoty IFS front axle design... anyhow I was curious to know if I could just buy the hubs from this truck and combine it with the later model solid front axle and that way keep the older lug pattern and also have a SOLID front axle... is it fairly simple bolt together or is it a PITA?

[ironmanandy]

The hubs are different. My wife asked me to not answer the phone on holidays.... I figured that was fair to her. A full floating axle has hubs on the outside to support the load on the wheels. The Dana 60 axle you have is a full floater.

A semi floater like a Dana 35, 44, ford 8.8, Chrysler 8.25 etc. is all one piece and the axle itself endures all of the weight and strain of the wheels.

A full floating axle is stronger and much easier to replace a broke shaft as all you have to do is pull the 8 bolts, fish out the broken parts and slide in a new shaft.

You can also drive home if a shaft breaks because the axle has a hub to ride on.

Just pull the 8 bolts on the shaft and count the splines.
A

[XJ4IV]

OHHHHHHHHHHHHHHHHH Ok well NOW im excited... I saw a youtube vid where a guy pulled his axle shaft out without even taking the wheel off or even jacking up the jeep ... I was REALLLLY wanting that setup SWEET guess I made ONE good decision lol now lets pray for my front axle decision... I iwill try and tear open the rear this week and post pics of whatever I find as far as ratio and spline count... I THINK i read somewhere that the E-vans all were eqquipped with 35 spline... I KNOW I read SOMETHING that made the van more desirable to get axles from but I cannot recall what!

[ironmanandy]

I used to go to the pull a part in Charlotte and pull ever shaft in the yard. I only ever found 2 or 3 of the 35 spline setups They are rare but, you will be fine with the 30 spline. You don't have the gears or the power to hurt those shafts.

Ghost from naxja (really good buddy of mine) runs a locked 30 spline 60 on 42s with a doubler and a healthy I6 and has had no problems.

A

[XJ4IV]

would it hurt to go to 5:13 gears on factory engine and tranny??? MIghtg eventually get the 231 and do the terra low kit but thats over a period of time!

[TeXJ]

would it hurt to go to 5:13 gears on factory engine and tranny??? MIghtg eventually get the 231 and do the terra low kit but thats over a period of time!

on the 231, i would scrap that and think a lil stronger. I would like to get the Rocktrac, for got the model#, that came in the rubicons. They already have the 4:1 and sye, the money you'd spend on a 231 would be real close if not more than you could get one for. Also, Used Atlas T-cases can be had for around the $1,100 mark, last i was looking at them. But that has been some time ago.


On the gearing the lower gearing from what i know/think would help the motor and tranny as they dont have to work as hard to turn those big tires/tyres for those across the pond :D

[4.3LXJ]

That is the NP241OR that has the 4/1 and heavier chain. If you run those 37 or 38s, 513 or a little deeper is the right choice. I will be running 5.29s for my 38s

[ironmanandy]

Gears always help the engine/trans. They help auto trans more than anything.

The lower gear you go, the weaker the pinion gear will be, as it has fewer teeth. You also are able to put more torque to the wheels putting more strain on the shafts. My personal rule has always been 4.56 and numerically lower is ok for smaller spline shafts (27-30) but once you get to 4.88 and up its wise to go ahead and try to run more beef in the shaft department.
A

[TeXJ]

Gears always help the engine/trans. They help auto trans more than anything.

The lower gear you go, the weaker the pinion gear will be, as it has fewer teeth. You also are able to put more torque to the wheels putting more strain on the shafts. My personal rule has always been 4.56 and numerically lower is ok for smaller spline shafts (27-30) but once you get to 4.88 and up its wise to go ahead and try to run more beef in the shaft department.
A

thats what i was thinking, but somebody with actual real world experience is always better, remember im an E-warrior :sniper:

I would think that him being only on 38's with a stock 4.0L i think 5.xx would be fine. what do ya think? Is that too low?

[4.3LXJ]

It is not going to be a problem with a D60 and 38s and only a 2.71 drop in the tcase.

[XJ4IV]

well Im gonna angle the rear axle 4 degrees so it kinda points at the case a little better... I installed a 4 degree shim in the rearend f my 35 and it worked wonders on the driveline vibes... anyhow back to the 60, I pulled the shaft today ... GOTTA LOVE THAT YOU CAN DO IT IN THREE MINUTES start to finish!
sadly but still its better than what I had its a 30 spline count... but dont I just need to upgrade the spider gears to be able to run the 35 spline? or does that call for a larger carrier as well?

[4.3LXJ]

I read a post recently that you had to bore the spindle with a tool from Randy's Ring and Pinion. Another alternative that is cheaper is to have the axles cryo treated and that will bring them up to 35 spline strength. Cost from Longfield super axles for this is $45 per axle.

[TeXJ]

im thinking the 30splined will be fine for you. Think about it like this there are plenty of people in full size rigs with V8s and heavier than you are, and they are on 38s+

[XJ4IV]

well I might have a line on a front axle out of a 97 f250... a guy in San Antonio is trying to part out his truck ...well at FIRST he was trying to sell it for 1200 but then I asked him what motor it had and tranny... and apparently he has an allison tranny and a 7.3... I told him those two parts ALONE are worth about 2500so he decided to part it out... so I offered himan Amplifier that I have had laying around for years, well that certainly perked his interest so he is trying to decide what he wants to do with it...waiting... STILL WAITING:indifferent0028:

[BrianXJ]

Tell him to hurry up and decide already lol

[XJ4IV]

been callin the guy no answer no return calls... thinking HE was blowin smoke up my ***... I hate when that crap happens!

[XJ4IV]

Picked this up today! WOOOOHOOOOOOO
http://i1133.photobucket.com/albums/m590/XJ4IV/Mobile%20Uploads/IMG022.jpg
and ordered these last night from ballistic Fabrication
http://www.ballisticfabrication.com/assets/images/newbrackets/ultimatebracket1.jpg

http://www.ballisticfabrication.com/assets/images/newbrackets/panhard-axle.jpg
Now all I need is to redesign the shock mounts on the frame side for the rear and a few wheel adapters and brake lines and a Driveshaft solution... and possibly a 231 case

[TeXJ]

i would really try and get the rock trac T-case from the rubicons if you can swing it. A 231 with a SYE would be ok. Just depends on gearing and if you ever twin turbo your motor :D

[XJ4IV]

Id LOVE to... but finding one would be harder than coming up with the extra green to buy it. Id be able to have enough money to buy a 231 ... DO the SYE kit and also BUY and install the terra low before I could FIND the rubi case for sale

[XJ4IV]

oh and Im gathering Info for my next major mod... V8 swap!!! leaning towards the 5.9 but with the bad luck I had on the Durango might go a different route. might do the smaller ZJ V8 then it should sue the same motor mounts and I could use the same transmission...I THINK!

[TeXJ]

what about the LQ9 out of the chevy's? much rather have a chevy motor than a dodge truck gas motor.

[XJ4IV]

I may have scrapped that idea after a briefing with Ironman.... thinking just bore the 4.0 out to a 4.6... YEAH

[TeXJ]

That is even a better idea, stroker baby!

[4.3LXJ]

what about the LQ9 out of the chevy's? much rather have a chevy motor than a dodge truck gas motor.

Once you get into OBDII engines there are other things that some of the computers require such as air bags and so forth that we don't have. If you want to look at possibilities, check the painless wiring website for possibilities.

[TeXJ]

they have companies that make items where you can "delete" or fool the computer to thinking that all is well.

but i think a stroker motor is a better option.

[XJ4IV]

I have an airbag... LOL it doesnt WORK but I have one!

[4.3LXJ]

Some people have them in the passenger seat

[XJ4IV]

Ok so Im sorry that its been more of a dana 60 PURCHASE thread but HERE WE GO...Today I had some "alone" time and got busy with the 60's I pulled my arsenal of metal working tools and went to town on the front axle as THAT one requires the most work and I have yet to get my rear leaf brackets, anyhow without further adieu here is what I did today
removed that STUPID overly HUGE bracket from the passenger side...
WHAT A PAIN IN THE...
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0821.jpg
Also was able to remove the perch plate without damaging it so I can POSSIBLY reuse it
This is the lower bracket... took me about an hour of grinding cutting hammering and thinking to get this sucker off but in the end I just picked up on the sway bar and POP it came right off
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0823.jpg
I was able to slavage what apears to be a track bar...
Im going to attempt to use this for my jeep track bar and send the one I bought from ballistic BACK to em since it really isnt going to work... Im not sure yet
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0822.jpg
sooooo tomorrow Im gonna tackle the rear axle and remove the factory spring plates
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0824.jpg
and Im gonna break out the ole router and open these suckers out a little bit
to fit over my ford hubs
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0825.jpg
so there you go guys... like I said before when I get a HOUSE with a GARAGE the build will start flyin by...
basically all I need NOW is the gears and a driveshaft!

[XJ4IV]

oh and I need tires but i THINK i might have found a set of goodyear MT/R's for 600 with 80% left on em... gotta LOVE craigslist!

[bluedragon436]

Build looks like it is coming along quickly now you got a place to work on it.. Can't find any good deals like that on our Craigslist... One more reason why, I want to move to TX!!

[XJ4IV]

come on down... there MORE than enough room and we dont care where your FROM we just are happy about where you ARE NOW!

[Switch_knuckles]

i'd like to do a D60 swap....................... someday.... Good luck with the build.

[XJ4IV]

I should be building these up tomorrow as well...
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0797.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0796.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_0795.jpg

[alwaysxj]

sweet, I cannot wait to see this think on tonz... it is going to be sweet.

so are you going 60/14 or 60/60?

[XJ4IV]

60 front n rear... I was not up for the challenge of shaving the 14 and doing it CORRECTLY! anyhow the 60's are probably overkill for me anyhow but its kinda like putting full coverage with a 100 deductible in a pinto! I am PRETTY sure I wont break these things... I might even need to alter my driving style to be MORE aggressive on the rock trails!

[XJ4IV]

Alright so I got 3/4 of the day devoted to the 60's which included Home Depot and Offroad unlimited!
so again without beating around the bush here are pics!!!
First I marked on my garage floor the centers of each coil using a plumb bob
never thought Id use one of those!
http://i1133.photobucket.com/albums/m590/XJ4IV/Plumbob.jpg
I also marked the center of the rear leaf springs on the garage floor using the plumb bob
Then I split the difference between them to get a center point between the centers of the leaf spring mounts
http://i1133.photobucket.com/albums/m590/XJ4IV/centerbetweenXJaxle.jpg
the NEXT thing to do was find the center of the 60!... kinda a pain to find two points on each side that were identical in plains (geometry is fun)
anyhow the center is actually about 1.75 inches off from the center of the housing... but whatever Im glad I did it this way and not just did center of housing
http://i1133.photobucket.com/albums/m590/XJ4IV/centerofaxle.jpg
so I THEN leveled the axle based on the perch plates
http://i1133.photobucket.com/albums/m590/XJ4IV/OElevel.jpg
and then I added a shim I made using my cool miter saw, I opted for 5 degrees which is what shims I used for my POS d35 so I SHOULD get the same pitch.
http://i1133.photobucket.com/albums/m590/XJ4IV/OEplus5.jpg
then I rotated the axle a little to make the 5 degree addition level
http://i1133.photobucket.com/albums/m590/XJ4IV/5degreepitch.jpg
then on to the hardest task of the whole project (besides shelling out the clams in the first place) Removing the stupid OE perch plates.
here is the driver side cleaned up and ready to go
http://i1133.photobucket.com/albums/m590/XJ4IV/Cleaned.jpg
I need to fill a few little grooves from the grinder...
here is the drivers side mocked in place
http://i1133.photobucket.com/albums/m590/XJ4IV/newperch5degrees.jpg
and here is my newb beginners tack welds
http://i1133.photobucket.com/albums/m590/XJ4IV/Tackedin.jpg
and for those of you who will critique my welding skills PISS OFF!!! i JUST started welding
never took a class never was taught
http://i1133.photobucket.com/albums/m590/XJ4IV/weldedin2.jpg
then I cleaned it all up and came up with this
http://i1133.photobucket.com/albums/m590/XJ4IV/Pretty.jpg
and after I finished the passenger side as well I then moved over to the H2 wheels, I had to open them on just a hair so I opted for the notoriously easy method of using a router with a 1/2 flush bit... WHAT A POS BIT i bought it "did" the job but it totally screwed up as the roller kept locking up and twice the bit came out of the router and it also broke one of the flutes... needless to say its going back!
Anyhow here is the ONLY good one that Im willing to show you guys! lol
http://i1133.photobucket.com/albums/m590/XJ4IV/machinedH2.jpg

Sooooo basically all I have left to do is obtain the upper link mounts for the front axle and then mock and install the front brackets THEN get drive shafts modified and obtain gears and install them and also get tires... not too bad huh!

[4x4Dalton]

Sweet bro cant wait to see how it all turns out.:thumbsup:

[XJ4IV]

me either LOL its kinda funny When it comes to this jeep... the ONLY thing that slows me down is the planning and funding, and ironically the planning sometimes takes longer than accruing the cash from selling stuff!

[XJ4IV]

i'd like to do a D60 swap....................... someday.... Good luck with the build.

the easiest way to do it is buy the small stuff over a period of a few months like 6 months and then when you get everything THEN start looking for the axles. IF you have a place where you can get half off deals... try and get the front axle first its the unicorn to find the one that EVERYONE is gonna tell you that you ought to buy... a 78 ford kingpin... ive yet to see one at a JY so I opted for a regular hub unit it will just require a little more fabrication!
good luck on your decision though I hope you can go for it!

[JRW7072009]

Just reading this thread for the first time and I see some that think BJ D60s are not as good as the King pin. There are tons of people running BJ Dana 60s, there is nothing wrong with them at all IMO.

I think some confuse with the BJ Dana 60 comes from the Dana 50 used in the 98-04 F-250.

The only two issues with a BJ Dana 60 is the ball joint and the diff is farther to the driver side and makes it a little harder to work with. However Ballistic fab has made a fix for both if those issues.


Cant wait to see more progress!:popcorn:

[XJ4IV]

Just reading this thread for the first time and I see some that think BJ D60s are not as good as the King pin. There are tons of people running BJ Dana 60s, there is nothing wrong with them at all IMO.

I think some confuse with the BJ Dana 60 comes from the Dana 50 used in the 98-04 F-250.

The only two issues with a BJ Dana 60 is the ball joint and the diff is farther to the driver side and makes it a little harder to work with. However Ballistic fab has made a fix for both if those issues.


Cant wait to see more progress!:popcorn:
whats the fix with ballistic? I bought all my brackets from them and I mustve not seen it? mostly cause I was re-designing the whole 60 and NOTHING on the jeep really

[JRW7072009]

whats the fix with ballistic? I bought all my brackets from them and I mustve not seen it? mostly cause I was re-designing the whole 60 and NOTHING on the jeep really

Well the Ballistic brackets are made so you can run coils and center the axle under the Jeep, before the issue was there was no space between the diff and the inner C to run any kind of a bracket. Before most people would just run air shocks.

And as for the Ball joints I thought they where making a bomb proof BJ but I guess its for the D44. You can still upgrade the BJs so they are stronger and last longer.

Here is a good thread on a bracket setup on the BJ dana 60
http://pirate4x4.com/forum/showthread.php?t=830206

[CONDUCTORICK]

Great thread, its allways good to hear the technical stuff but even better when ou the pics for guys like me that have no idea what you are talking about till I see it. Thanx

[XJ4IV]

Well the Ballistic brackets are made so you can run coils and center the axle under the Jeep, before the issue was there was no space between the diff and the inner C to run any kind of a bracket. Before most people would just run air shocks.

And as for the Ball joints I thought they where making a bomb proof BJ but I guess its for the D44. You can still upgrade the BJs so they are stronger and last longer.

Here is a good thread on a bracket setup on the BJ dana 60
http://pirate4x4.com/forum/showthread.php?t=830206

oh yeah those are the ones I purchased, look above your original post

[XJ4IV]

well apparently I dont have the SKILLS required to do this myself as one stated! so Ill just take this thread somewhere else and for those of you who care about watching this build and seeing what a ROCK CRAWLER can do by all means send me a PM and for those of you who want to critique my ways ... I dont see YOU venturing out and trying a lil out for yourself!

[4.3LXJ]

Hey Scott, someone rub you the wrong way?

[bigjim350]

well apparently I dont have the SKILLS required to do this myself as one stated! so Ill just take this thread somewhere else and for those of you who care about watching this build and seeing what a ROCK CRAWLER can do by all means send me a PM and for those of you who want to critique my ways ... I dont see YOU venturing out and trying a lil out for yourself!

Oh no sir i did not mean to imply that you werent a highly skilled welder. I simply pointed out that you have only been welding for about a week.. I have been welding many years and still get a little worried when im welding on brackets that hold the axles under my jeep. And like i said in the post that got deleted, up until now i would have loved to help you out. But now that you have such a great welder that you are so skilled with, how bout giving my old one back :D

[4.3LXJ]

Hey guys, how about we back up and bury the hatchet. Jim, would you still be willing to help him with those brackets?

[bigjim350]

Sure would, just as soon as I get my old welder back. Which I have a feeling he doesnt even have any more. But other than that would be happy to help as long as will let me help and not tell me how to do it.

[4.3LXJ]

How about it Scott, want some help?

If you weren't so far away, I would let you bring them to my shop and let you practice and burn that stuff on for you

[Mudderoy]

Scott contacted me via PM and asked that his account be deleted. You may need to look for him on other Jeep sites.

We're sorry to lose Scott, I know I personally enjoyed him and I was enjoying watching this build.

These things happen, and it's always sad. :patriot:

[XJ4IV]

ok its been TOOOOOO DAMN LONG.. anyhow now that we are back in a house and I have plenty of room to stretch out and work... so without further adieu here is todays progress
so first things first I ran into a small issue that I really cant get around the track bar and the pumpkin are gonna get to know each other REALLY well
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1802.jpg
Ive decided to remove that upper support and move the track bar up to the higher location and remove about 3 inches so I can have SOME up travel
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1800.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1789.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1788.jpg
so after some measurements it looks as though this will be my official width
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1797.jpg
however the height might be another 3 inches higher... which I really didnt want
and if this is the situation then I really guess Im gonna have to coil the back
lets hope I don't have to do that!!!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1798.jpg
as you can see the centerline is about an inch lower than what the finished product will be
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1793.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1785.jpg
ok so now to the most crucial part for ME to commit to... the shock tower build and install
the shock hoops are gonna be mounted on the front side here
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1794.jpg
and the back is gonna go here
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1796.jpg
and this whole chunk is gonna come out
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1795.jpg
this is pretty much what it should look like when finished
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1784.jpg
I forgot to check this out but I need to see about the drag link mounting up to the pitman... I might need to reem out the OE pitman arm to allow for this joint to fit... this will be on the agenda tomorrow
other than what you see here the things I dont have in my posession are:
link mounts ( ones I WAS gonna use wont work)
brake calipers
rotors
YJ brake lines
16 lugnuts for front
16 lugnuts for rear ( they are different thread
rear spacers to match the track width of the front
track bar mount axle side
u-joints... ordered em just need to pick em up
and one single 37/13r17 bogger!

Finished specs are:
60's front and rear
lincoln locked
5:13 gears
37 boggers
Fox 2.0 air shocks
about 8 inches lift maybe 9

[ironmanandy]

Lookin good!

[TeXJ]

x2!! Very nice!

[XJ4IV]

andy Im soooo SORRY that Im going to need to modfy the track bar mount, I REALLY dont wanna have to do that however it looks like I have no other choice unless I dump TONS more money into this which Im in pretty deep thus far but STILL under 1000... patience pays off

[XJ4IV]

lets see here price total thus far
tires 50$
front axle 250
rear axle 185
calipers are about 100
rotors lookin at about 100 as well
brackets 75
wheels 250
front lug conversion adapters 100
rear spacers to match front 100
front gears 155
rear gears 100
oops guess I didnt do the math in my head very good... and I forgot a few things in my rough guestimate sooo ok 1715 is lots higher than I expected however I did this over a course of a year and think of how much everything would cost at retail prices,
the tires alone would have cost tht much
gears would have been about 400 for the set
the AXLES well who would buy those new anyhow

[XJ4IV]

So I got my new rear driveshaft u-joint in today... wait for it....
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http://i1133.photobucket.com/albums/m590/XJ4IV/IMG141.jpg
hopefully I shouldnt need a trail spare...

[XJ4IV]

well as MY luck would have it ive hit yet ANOTHER damn financial road block!
still waiting on a deal for calipers... looking like ebay for 100 for the pair

[4.3LXJ]

Scott

Iwas thinkimg about your front axle. Instead o5 modifying thfe track bar mount, why not have Andy , make you another lomger one that will clear and be the right length for your new drag link

[TeXJ]

HOLY HUGE u-joint!!

[Mudderoy]

So I got my new rear driveshaft u-joint in today... wait for it....
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http://i1133.photobucket.com/albums/m590/XJ4IV/IMG141.jpg
hopefully I shouldnt need a trail spare...

Man you got screwed. That isn't new! :shocker:

[XJ4IV]

Scott

Iwas thinkimg about your front axle. Instead o5 modifying thfe track bar mount, why not have Andy , make you another lomger one that will clear and be the right length for your new drag link

because Im broke as it is for 1 and for two the track bar is fully adjustable and thus far no mount on the axle side yet so I can pretty much but it anywhere no worries Ill make it allllll work... i think tomorrow im gonna cut the holes for the shock mounts and locate some DOM to make the shock hoops... I GOTTA get this thing under its own weight!

[ironmanandy]

Just remember you want the track bar to be the same length as the drag link.
A

[XJ4IV]

yes sir, thanks for the reminder!

[XJ4IV]

got the shock hoops bent today...
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG146.jpg
so on the passenger side I have to move three things... any ideas on WHERE these items should go?
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG143-1.jpg
driver side LOOKS like more room however ... WTF am I gonna do with the master cylinder? I dont have ABS anymore so I know I can remove that whole dang thing but I need a proportioning valve for non ABS I guess...
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG145.jpg

oh and all measured up ... Looks like I get to run the hoops through the hood like this
http://i283.photobucket.com/albums/kk302/ultimate94zj/otherjeepstuff040.jpg

[bluedragon436]

That is a beast of a WJ right there.. would love to have something like that one day.. I think something like that through the hood wouldn't look too ridiculous... you going to connect the towers under the hood too, that way they have support against each other??

[XJ4IV]

yeah Ive decided that the shock tabs will do two things... go downward for the shocks and inwards for the center support... it sounds gay but I have a cool design in mind which will be removable as well

[Mudderoy]

That tube looks thin. So it doesn't have to be the thick wall stuff? Maybe I'm just seeing wrong, but it looks like that tubing they use on the storm fences from the picture.

[XJ4IV]

its galvenized however it is not fence pipe, it has been galvenized for outside storage
its the same thickness I have for my rock rails rear bumper and front bumper... thos far THOSE have held up DAMN good

[bluedragon436]

yeah Ive decided that the shock tabs will do two things... go downward for the shocks and inwards for the center support... it sounds gay but I have a cool design in mind which will be removable as well

Yeah I was figuring you would make it removable in case you have to replace the engine, or take it down for any reason.. Not to mention I would think it would help strengthen the front end up a bit as well.. I can't wait to see how your build goes..

[msmoorenburg]

why don't you look into some mandrel bent tubing? I would think it can handle the pressure better than a tube that kinks during you bends.

[ironmanandy]

I would be very cautious with the tubing that is kinked. It creates shears in the tubing before it is even in use and there is alot of force on those mounts. If its just for a shock it should be ok. If its for load bearing, air shock or coil over it will be a very high stress point. I have seen these mounts let go and it just breaks everything around it.

Those tons are heavy. They will create more force on your jeep than before.
A

[XJ4IV]

damn! I was going to get those tabbed up today

[Mudderoy]

Yeah I want you to hurry up and get this together so I can look at it :popcorn: but not at the risk of your XJ, or worse you and the kids.

[TeXJ]

@ muddy word!

[bluedragon436]

Yeah can't wait to see this completed.. but def. not at the safety of yourself or family!!

[XJ4IV]

Now accepting donations... Alllllll donations will be publicly thanked... and Im sure somehow GREATLY rewarded... those shock towers are 48 inches long prior to bend
and the bend is ... well crap I gotta check that but somewhere along the angle of 45-50 degrees

[Showtime3492]

:popcorn:

[msmoorenburg]

i have some schedule 40 pipe 90 degree bends somewhere

[XJ4IV]

dang... any possibility to bend it more than 90... I think close to 45 degrees...

[XJ4IV]

So I was talking with someone on another forum and found out a VERY annoying discovery ... My front axle is a d50... not a d60!! SON OF A BATCH OF COOKIES!!!
so the question I have NOW is do I sell the ring and pinion and carrier I bought for this ORRRR do I scrap the 50 and go for a 60... or WTF DAMN jeep is on back burner AGAIN!!!

[4.3LXJ]

Scott

You don't really need a ten inch ring gear in the front. It is just extra iron. The real advantage of 60s is axle shaft size. IIRC the only weak point if you can call it that is the stub axles, which is reduced on many 60s also

[XJ4IV]

Yeah I just found a set of gears on polyperformance for 185 free shipping for the 50 so I think I might be able to sell these for that much!
is there a carrier break I need to be aware of? I bought the bigger carrier for the 60 as well as the gears so I pretty much have a drop in with new carrier bearings

[dagr8tim]

Looks like an awesome project. Can't wait to see more.


http://www.youtube.com/watch?v=I4jHOkcJn4c

I know that guy, he's in my Jeep Club. Here are some more vids of his monster.

http://www.youtube.com/watch?v=nKKgvIpvZps
Fast Forward to 2:37

http://www.youtube.com/watch?v=rnHu_Gj2Nnc
Fast Forward to 3:47

[4.3LXJ]

Yeah I just found a set of gears on polyperformance for 185 free shipping for the 50 so I think I might be able to sell these for that much!
is there a carrier break I need to be aware of? I bought the bigger carrier for the 60 as well as the gears so I pretty much have a drop in with new carrier bearings

Not sure on the carrier break, but any Dana axle I can think of has one. The easiest way to find out is cruise Randy's Ring and Pinion website. If it lists two carriers, then there is a break.

[XJ4IV]

well I suppose theres SOME light at the end of the tunnel...
it seems there are no breaks in the carrier
http://www.ringpinion.com/DiffDetails.aspx?DiffID=143&SearchMode=Diff&TypeID=3&Diff=Dana+50+Front%2c+Straight+Axle

[4.3LXJ]

Looks like the axles are only 30 spline though

[XJ4IV]

Looks like the axles are only 30 spline though

Eh matches the rear... LOL still better than the 30/35 setup RIGHT!

[4.3LXJ]

Oh yeah. But when you are feeling rich you can upgrade to 35 spline

[XJ4IV]

inners AND outers? and would I need to swap the hubs as well??? seems like a lot of work... how about when I BREAK it THEN I can upgrade it!

[4.3LXJ]

Sounds like a plan

[4.3LXJ]

Just had a thought, my only one for the day. If you take those 30 spline axles and have them cryo treated, for like $45 a piece, you can have the strength of 35 spline axles. Very cheap upgrade.

[Showtime3492]

In those vids i watched that exact cherokee demolish a rock garded on youtube a while back. I was jaw dropped then and i am now...

[XJ4IV]

can I get the inner and outter cryo'd as a whole unit? or do they HAVE to be seperate?

[Mudderoy]

Just had a thought, my only one for the day. If you take those 30 spline axles and have them cryo treated, for like $45 a piece, you can have the strength of 35 spline axles. Very cheap upgrade.

lol I misread that at first. I read "you can have the strength of Dana 35 axles" :bang:

[dagr8tim]

In those vids i watched that exact cherokee demolish a rock garded on youtube a while back. I was jaw dropped then and i am now...

I had a better vid of him destroying that rock garden, but can't find it. About an hour before the sky opened up and dumped like 2 inches of rain in less than an hour. The rocks and the hill were really really slick.

[4.3LXJ]

can I get the inner and outter cryo'd as a whole unit? or do they HAVE to be seperate?

I think you will probably have to break them down. There might be a grease contamination issue as well as destroying the ujoint seals. Liquid N2 is really, really cold and not good for organics. But call them and find out. One guy that does it and is good is Bobby Longfield. He will give you all the info free.

[XJ4IV]

wonder if there is someone here in texas? I get around in this great state so I could just about bring them anywhere for no shipping

[Showtime3492]

I had a better vid of him destroying that rock garden, but can't find it. About an hour before the sky opened up and dumped like 2 inches of rain in less than an hour. The rocks and the hill were really really slick.

That jeep makes me feel like mine is an piece of trash and should be picked up and thrown away immediately before that thing comes along and eats it... :headshake::headshake:

[bluedragon436]

^^ I'm with him.. that thing is a beast!! Don't think it would do very well as a DD and weekend wheeler though... so maybe mine isn't soo bad...

[Showtime3492]

^^ I'm with him.. that thing is a beast!! Don't think it would do very well as a DD and weekend wheeler though... so maybe mine isn't soo bad...

Lol its okay someday my jeep will be a real boy till then im sure he is :mock: at all the other lifted xjs

EDIT: Sorry for the hijacked thread :)

[XJ4IV]

That jeep makes me feel like mine is an piece of trash and should be picked up and thrown away immediately before that thing comes along and eats it... :headshake::headshake:

Heeeeyyyy thats what Im shooting for!!!

[dagr8tim]

As impressive as that thing is on video, it's even more amazing in person.

[XJ4IV]

OK so I was able to sell the 60 gears... I gotta order the fronts ... I can get yukons from polyperformace for 260 shipped ORRR I can get some from performanceoffroadcenter.com for 221.00 plus 29 shipping, not sure what brand yet I gotta call em

[TeXJ]

Just an FYI PORC used to be a sponsor on pirate, then people started having problems with their shipping, like not getting product but still being charged...so fyi

[XJ4IV]

Hmmmm well THAT being said... I suppose Ill get the Yukons from poly

[4.3LXJ]

Hmmmm well THAT being said... I suppose Ill get the Yukons from poly

You an buy them direct from Yukon too. Use your company you work for and get their discount

[TeXJ]

Thats why i went to Randy's Ring and pinion

[TeXJ]

You an buy them direct from Yukon too. Use your company you work for and get their discount

not there anymore :bang:

[XJ4IV]

Still can get a decent discount though... Im sure he would still probably give me the same discount as when I was there... we are still friends just business was too slow to keep us on...

[XJ4IV]

Sooooo Its been a few since an update, well I got me a decent set of rubber to hold me over until I can swing 800 bucks for two boggers, also built a extension cord for my welder so now I can finally start welding things in place... I should have done stuff today but damn it felt great to not do anything today!
IF I get calipers next week then Im going forward with the build.
I have a bid on ebay for front gears so we shall see how that goes!
wish me luck!

[bluedragon436]

Good luck on the auction, Scott... I seriously can't wait to see how this progresses..

[XJ4IV]

Good luck on the auction, Scott... I seriously can't wait to see how this progresses..

me neither LOL

[XJ4IV]

HA I won the auction, they shipped yesterday morning, the guy also gave me a new crush sleeve new pinion nut and ring gear bolts and shims... pretty cool guy if ya ask me!
Ok so I was mocking control arms into place and came up to a fairly large problem... since the axle is SO wide and the mounting of the driver side is VERY limited on space and basically the spot where it would be mounting is in line with the OUTside of the "frame" rail, that being said can I modify my cross member on the outboard side to have my lower links go straight to the axle on the outside of the frame, and the NEXT question is can I delete the uppers on the sides and make one single upper in the center? basically a three link I suppose.

basically here this for the uppers but yeah a bit more stronger
http://www.dredracing.com/albums/3linkFeb2006/aaa.sized.jpg
and the center link to look like this except mine would be centered rather than on the differential...
http://www.central4wd.com/_files/_images/TrailLinkFront_Header.jpg
if this is a reasonable solution then Im good! :thumbsup:

[ironmanandy]

Stay away from poly on a 3 link!!!!! As a guy that stands behind poly bushings and promotes them all day long DON'T DO IT !!!!!!! A 3 link puts too much force on the links. It will fail. Stick with Heims or Johnny joints. I know heims wear out after about a year but they done break or split or just fall apart under pressure. Johnny joints just plain work! They don't break. They rarely wear out. I have never replaced one.

Don't skimp on that link setup. It will not end well.

Good luck.
Andy

[TeXJ]

Andy you're so handy!

[XJ4IV]

Yeah Ive made a commitment to stick with heims due to the odd triangulation Im dealing with... Im curious with the setup I already have, can't I just use the passenger side upper link? and just not have a driver side upper? Ive seen a handful of rigs sporting just the one upper and most likely for the same reason no room

[4.3LXJ]

I am doing that currently but with the driver side. I am using a poly bushing I had for the front spring of a Chevy K10. I know for a fact you cannot use the rubber ones. They last about a day on a three link. So far, no issues.

[XJ4IV]

well my current setup is the HD Ironman4x4 longarm which used the OE d30 bushing...

[4.3LXJ]

Scott, that bushing is going to have to be much tougher to stand up to being alone. You might be able to engineer yourself out of some of the dilemma. The reason the bushing does not stand up to being by itself is that the spring sits forward of the center of the axle in the stock position. So when the weight of the vehicle is on the axle, the top of the axle is pulling forward. When you hit a bump (something yo should never do in a mall crawler right) that upward force gets magnified many times particularly on lifted rigs due to the higher spring rates commonly used. That will simply beat the stock single bushing out. So to correct some of that you can move the axle forward so the spring, or coil over is sitting directly over the axle. That will even out the forces more and make that single bushing last longer.

[LizardRunner]

Or do like Andy says and put in Johnny joints.

[4.3LXJ]

Yes, you can do that. The ones from Parts Mike might be better for you. Larger and are supposed to wear longer.

[XJ4IV]

OK new direction, Ive gotten sick of the whole timely modification for the air shocks and shock towers and all the extra crap I gotta do, I placed the coil bucket brackets back in place and found that I can really just stick to coils and have a better on road ride, so Im going that route... now hopefully I can finish VERY soon. UGH been a LONG time coming! soooo up for sale a pair of BRAND NEW never used 16 inch travel FOX air shocks... 375 for the pair! they were about 450 new so a pretty damn good deal! and shipping is on you ! you get what I got the two shocks install manual and the hardware!

[4.3LXJ]

Scott

I think that is a wise decision. You really do have to redo almost everything to get that kind of travel. I am at about 12" and had to do a lot to make it work right.

[XJ4IV]

well with my previous setup coils and everything I had CRAZY travel I mean Geez
http://i372.photobucket.com/albums/oo167/seivey/BVORR%20November%202010/IMG_0128.jpg
so I guess I will sell off the goodies and get back to a "normal" setup, heck this way I can even drive it on the highway well until I install the gears!

[ironmanandy]

If it were just a dana 30 I would not worry about it. I still think running one upper link on a radius arm is half ass on a d30 but on a 60 that weighs gobs more and with tires that will create so much more leverage on the links you should not do it. If you do a 3 link make it massive. Send me a picture directly under your jeep so I can see your crossmember and clearance to your exhaust and drive shaft.

take another picture of the front axle from under the jeep from behind. Even if you use 2 1.5" links with a 7/8 hiem for uppers you will be much much better off. Just cut the radius arm mounts off my lowers and be good.

Andy

[LizardRunner]

I have to agree with Andy. When it comes to suspension parts I don't think there are such things as "Over Kill" or "Too Beefy". I do think you can hit "wimpy" very quickly though.

[4.3LXJ]

I agree with that too. Finally got my wimpy problems solved.

[XJ4IV]

well since Im moving the lowers outboard this gives me enough room to use the radius setup again so Im sticking to a traditional setup i MIGHT have rubbing issues but I doubt it rubbing tires to arms that is

[Firemanray]

Are you using different control arms? If so I would be interested in the ones you have now.

[XJ4IV]

no Im using the same ones, since Im moving them outboard i can utilize the same ones, I just gotta make custom upper tabs on the axle!

[ironmanandy]

Currie makes a 2" joint that will work for your uppers it is the CE-9112p-12 Just drill out your uppers at the axle end to 1/2" build brackets off your axle that house the johnny shells and then rock and roll
Andy

[XJ4IV]

sweeeettttt I am able to get the tow rig up and running here over the next two weeks so I don't HAVE to rush the jeep build anymore but yes Im still sticking with coils but now I can do some more research ... like what andy has done for me LOL
and go with great quality parts!

[bluedragon436]

Get this thing done already... so I can come and pick up my 1 Ton upgrade that will be bolt-in ready for my XJ!! LOL.. Looking forward to seeing this as it comes along.. Maybe one day I'll have the knowledge to complete something like this on my XJ!!

[TeXJ]

Get this thing done already... so I can come and pick up my 1 Ton upgrade that will be bolt-in ready for my XJ!! LOL.. Looking forward to seeing this as it comes along.. Maybe one day I'll have the knowledge to complete something like this on my XJ!!

Scott's thinking the samething :D

Luv ya scotters

[XJ4IV]

damn right... Im trying to sell off the fox shocks... once those go I will be able to finish the ton build...and be done messing with upgrades until the stroker and steering which will wait till summer!

[XJ4IV]

Been a while but slight update on the way here
I installed my custom upper arm mounts fabbed by Krawltex in Austin Texas!!!
I gott all this stuff on order today to finish off all the little things I forgot about lol
ordered 2 of these setups from Currie Enterprises
http://www.currieenterprises.com/cestore/images/product//currie/ce9110p.jpg
ordered two of these as well, one side will be like this and the differential side will have to be hacked a little to make work
http://www.currieenterprises.com/cestore/images/product//currie/ce7110up1.jpg
and this guy... totally forgot about the trackbar
http://www.currieenterprises.com/cestore/images/product//currie/TJ-BRKT-FTB.jpg
and also forgot the steering stabilizer too so I got this guy
http://www.currieenterprises.com/cestore/images/product//currie/ce7110ss_new.jpg

I sold my swampers to get all this stuff!

[xjrev10]

Im going to be starting this same type project soon. If I could ask one favor.. could you link the parts that you have posted, and future purchases? Would help out alot!

Looks great so far, Ill be watching!

[bluedragon436]

Those parts look pretty beefy... At least you shouldn't have any issues with them!!

[XJ4IV]

Im going to be starting this same type project soon. If I could ask one favor.. could you link the parts that you have posted, and future purchases? Would help out alot!

Looks great so far, Ill be watching!

My BEST advice at this point is stop before you start lol a 1 ton build is a VERY extensive project and a TOTAL pain in the... save a few bucks and buy Chromoly shafts front and rear they prove to be JUST as strong as a dana 60 axle if I knew THEN what I know now(considering the hell on locating and buying parts for the front axle)I never would have wasted a cent on doing 1tons. I was HOPING to drop the front axle for under a grand.. THAT didnt happen!Im at nearly 1300 now!and thats not including the labor to weld everything and the hours of getting everything JUST right where its supposed to go!
but IF your going to still build one
here is a list of parts I ordered
If your using a heim on the axle end you can go this route for the track bar... which is what I WANTED to do but decided against it for financial reasons
http://www.ballisticfabrication.com/Panhard-Trackbar-Mount_p_1399.html

These for the rear axle
http://www.ballisticfabrication.com/Leaf-spring-perch_p_1485.html

these were not available when I bought my first kit... this one also has the trackbar mount on it along with the coil/shock/lower control arm mounts
http://www.ballisticfabrication.com/XJ--TJ-Jeep-combo-bracket-upgrade-kit_p_1542.html

or you can get this trackbar mount from Currie
http://www.currieenterprises.com/cestore/searchresultsRE.aspx?site=2&fullType=Price%20%28Highest-Lowest%29&text=TJ-BRKT-FTB

got two of these for the upper control arm mounts
http://www.currieenterprises.com/cestore/Product569.aspx?id=1261

ORRR you can go this route and buy one of each of these
http://www.currieenterprises.com/cestore/Product569.aspx?id=1261

http://www.currieenterprises.com/cestore/Product596.aspx?id=3354

I opted for the stand alone ones so I can make any needed modifications as far as aiming them more directly at the control arm mount on the frame side (or in my case cause Im using radius arms the lower control arm)
http://www.currieenterprises.com/cestore/Product596.aspx?id=3087
with these the passenger side one should be cut n dry but the driver side is gonna be tricky cause its gotta go ON the differential!

that should do it for the brackets on the axles... at least thats what I have purchased thus far

my gears were about 200 per axle I went with 5:13 richmond gears

and as for tires I went with 37" boggers

[XJ4IV]

got some work on the rear axle today
removed the diff cover and let it puke out some almost 30 year old 80/90 oil
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00577.jpg
pulled out the old carrier and removed the ring gear
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00578.jpg
cleaned out the housing a bit
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00579.jpg
went and set up the new carrier with the 5.13 ring gear and spider gears
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00582.jpg
went to start the painful removal of the pinion and realized its a 33MM not a 36MM nut... so I gotta wait til payday to get the correct socket!more to come!

[XJ4IV]

wow looking at that last pic kinda looks like the ring gear is gouged but it isnt... it is some marking compound so no worries

[TeXJ]

wow looking at that last pic kinda looks like the ring gear is gouged but it isnt... it is some marking compound so no worries

haha good eye

[xjrev10]

I know what the stuff costs. 1300 is chump change for a 60 front swap. I figured at least 2500-3000 just for the front not including the axle. Rear a bit cheaper at 15-1700 hundred. Tires are the BIG expense now it seems. Im going to use some 39.5 IROKS that are used for awhile.

Thank you for the links! Should help out alot. Got a buddy planning a 44 swap for his TJ and we have been searching for good brackets.

No problems with Ballistic Fab?

[TeXJ]

I know what the stuff costs. 1300 is chump change for a 60 front swap. I figured at least 2500-3000 just for the front not including the axle. Rear a bit cheaper at 15-1700 hundred. Tires are the BIG expense now it seems. Im going to use some 39.5 IROKS that are used for awhile.

Thank you for the links! Should help out alot. Got a buddy planning a 44 swap for his TJ and we have been searching for good brackets.

No problems with Ballistic Fab?

I've heard great things about Balistic Fab, plus they have a FB page lol

So you are spending 2500-3000 on a front 60...what about just buying a unit already done, like a currie, spidertrax or something along those lines?

[XJ4IV]

yeah a Currie Rock jock is like 3k already setup with gears n such... If I had that cash thats wht I'd have done!!!and yeah ballistic fabs stuff is great... however I JUST received my parts from currie and they used 1/4 steel to make some of the more important brackets soooo seems a little more stout! we shall see over next week or so... I might have the jeep finished today ... pray for us!

[TeXJ]

yeah a Currie Rock jock is like 3k already setup with gears n such... If I had that cash thats wht I'd have done!!!and yeah ballistic fabs stuff is great... however I JUST received my parts from currie and they used 1/4 steel to make some of the more important brackets soooo seems a little more stout! we shall see over next week or so... I might have the jeep finished today ... pray for us!

praying!

[XJ4IV]

I THINK I messed up ... I stayed home from church yesterday to work on the jeep ANTICIPATING a finished product... apparently God had other plans and he made that NOT happen however he DID sit there beside us while we were working cause everything we did was without a catch or any problems!
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00595.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00593.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00589.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00593.jpg
and the stance!!!
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00594.jpg

[4.3LXJ]

I like the look of that front end

[TeXJ]

who was helping ya? nice progress!

[XJ4IV]

new local buddy... hes not into the forums but he's a jeep guy... and he knows how to ARC weld

[bluedragon436]

That front end looks good Scott!! Would love to have that stance one day... but will be a while until I have the money for it... Can't wait to see it progress!!

[TeXJ]

replacing me already :'(

j/k :D

[XJ4IV]

replacing me already :'(

j/k :D

not a chance donner not a SINGLE chance:D
speakin of... isnt it OUR turn for a get together?
might do a shake down run to gilmer or bridgeport in april or so

[TeXJ]

not a chance donner not a SINGLE chance:D
speakin of... isnt it OUR turn for a get together?
might do a shake down run to gilmer or bridgeport in april or so

the election run is the end of this month.

school work is going to be pretty busy for me, we can try and swing something between semesters.

[xjrev10]

I've heard great things about Balistic Fab, plus they have a FB page lol

So you are spending 2500-3000 on a front 60...what about just buying a unit already done, like a currie, spidertrax or something along those lines?

Getting the axle for nothing. Big money is gears, ARB, steering, brackets, etc.

[TeXJ]

Getting the axle for nothing. Big money is gears, ARB, steering, brackets, etc.

little bit more and you can get a reinforced housing with better C's.

[TeXJ]

60 and 14blt ready to go...kind of...

http://www.lsjc.org/board/showthread.php?59418-New-Built-CUCV-Chevy-Dana-60-front-14-bolt-rear

incase you cant see it:
Just built Chevy 60/14 CUCV axles low miles

completely disassembled, steam cleaned, painted and rebuilt with my upgraded parts by professional shop. Was planning to install in my brothers CJ7 but we found a buggy so it's all for sale

Front - Dana 60, 4.56 gears, moser spool, 35spline shafts inner and outer, RPM offroad HD drive flanges, BTF diff cover, Ballistic high steer arms

Rear - 14 bolt, 4.56 gears, detroit locker, BTF bolt on disc brake swap kit, new calipers, BTF diff cover and pinion guard, new ubolt style yoke

Located in Sherman Tx
$4500 firm Reduced to $4000

[xjrev10]

little bit more and you can get a reinforced housing with better C's.

It's not what you buy, it's what ya build!

[Mudderoy]

It's not what you buy, it's what ya build!

That's what people say when they have to build everything. :smiley-laughing021:

Actually I know some people do like working on their stuff. I had to correct my wife the other day. She's been telling several people how much I enjoy working on my Jeep (and now hers). I told her I don't it! I do it because I want things done to it, and I don't want other people touching it. Especially the pay people as they never take the interest in it that I would.

She said that I seem to like buying tools. I'll give her that, it is fun to use a new tool, especially when it cuts the work down.

I do like the mods, and I do like that I do them, I just don't like doing it. lol

[TeXJ]

tony I'm with you on that one. I like to work on my jeep, however with school and work, I dont have time. If I can pay somebody to do something, I'm all for it so that I can spend my time wheeling. For me I'm also cheap, so I can buy a jeep pretty much done for half of what it would cost me to do it. Then I can tweak that and add my own stuff to it.

[xjrev10]

Sorry for the high jack here...

People ask me all the time if I'll work on there car, truck etc cuz they think I'm a mechanic. Nope. I like working on MY jeeps to make them how I want. My jeeps are the only vehicles I personally change the oil on for example. My dodge diesel, her liberty, all go in for oil changes. Folks find that funny. If it don't say JEEP on it, my tools dont touch it! I might work on a TJ or something for someone but that's about it.

[XJ4IV]

OK so my buddy came over tonight and we knocked out ALL the tabs for the front axle
the one on the differential used a nickle rod... apparently it burns MUCH hotter than standard 6013 rods... we melted the bushing on my new johnny joint... oh well Currie has said I can order a new rebuild kit and since im now a "current customer" I can get a discount 10% either way I gotta get a new bushing
Anyhow heres the progress
passenger side tacked in and finishing the track bar mount
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG128.jpg

http://i1133.photobucket.com/albums/m590/XJ4IV/IMG129.jpg

http://i1133.photobucket.com/albums/m590/XJ4IV/IMG130-1.jpg

here is the drivers side which you can see the bushing oozing out
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG131-1.jpg

and Jim this ones for you... gusseted
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG132-1.jpg

the bottom side of the axle for the track bar and the control arm ventral side
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG134-1.jpg

we made another pass on the differential bracket and it turned out much nicer
also cleaned up some of the hack job I had to do on the coil brackets to accomodate the cast tubing but its all good now...
Tomorrow the whole axle gets cleaned up and coated with bed liner and rolled into place and the front springs bolted on!

[XJ4IV]

so two hours later from burning the bushing I have the other ones on order now
Also ordered this guy tonight!
http://www.originmotorsports.com/ebay/rf/2xFAN.jpg I should be back in the saddle again REALLY soon

[TeXJ]

awesome!!! nice job!

[XJ4IV]

OK front axle in place... I might need to RE-do the control arm mounts on the frame side... It seems its binding a bit but here are todays progress

first off I sprayed it all down with degreaser and gave it a good wipe down then washed it THEN wire wheeled it bare...
Then I shot it with my favorite bedliner
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG142.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG141-1.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG140-1.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG139-1.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG138.jpg
wait for it.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00601.jpg
yeah I know the springs are not straight... that was expected... It was due to the lack of room on the outside of the driver side differential
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00602.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00603.jpg
and just for laughs... the tires in the middle are 36's which are what was on it prior to the upgrade... the ones ON the jeep are my "streeters" the boggers on the OUTSIDE are what are goin on there once I get a tow rig
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00600.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00597.jpg
Need to do a REALLY good alignement
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00596.jpg
Other than that I might move the lower mounts outboard and I should be golden... tomorrow the back axle!!! WOOP

[TeXJ]

nice job, and great looking axle!

[XJ4IV]

So I bought the socket for the rear axle pinion and pulled the pinion ... apparently im incredibly strong cause I removed the nut with ease

http://i1133.photobucket.com/albums/m590/XJ4IV/IMG153-1.jpg
Our internet is out this weekso updates might be slow but on the plate today is the driver side bushing replacement and rear gears and clean it out... hopefully my fans show up today , if so ill do that too

[XJ4IV]

Built me a new drive shaft...
So I went to a guy over the week to get my drive shaft shortened a tad since the new axle site closer to the t-case and I took some measurement... apparently again Im an idiot and gave him the wrong information... and I PAID him $40 for getting my drive shaft TOO short soooo NOW what?
well I decided to take what he gave me that he removed as a guide and started looking for a sleeve to lengthen the shaft a little more
This is what I found:
top right is OE drive shaft thickness
lower is part of an old axle tube I had laying around that had a seam in the center
and upper left is some steel pipe I obtained from a job last year that I never used( no seam on the inside)
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG196.jpg
OBVIOUSLY I opted for the seamless pipe cause it was thicker and required the LEAST work
so THEN I cut my drive shaft in half with my chop saw
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG191-1.jpg
and cleaned up the remnants
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG192-1.jpg
the new shaft which was 1.75 inches longer
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG193-1.jpg
dropped the cleaned up portions into the new sleeve
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG194-1.jpg
MORE than a perfect fit!
lined up the other end to be in perfect alignment and sunk the other end into place!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG195.jpg
these fit SO nicely I just had to tap them in very slightly
welded her all up and ground it down to a smooth finish
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG197-1.jpg
Installed into place!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG198-1.jpg
perfect OE fitment!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG199-1.jpg
and check out the clearance I got from angling my axle 5 degrees
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG200.jpg

[bluedragon436]

Definitely looks like a nice beefy driveshaft... Just sucks you had to pay the guy for a shaft that was too short.. At least you are good now...

[Mudderoy]

Definitely looks like a nice beefy driveshaft... Just sucks you had to pay the guy for a shaft that was too short.. At least you are good now...

Measure twice, pay once. ;)

[TeXJ]

nice job scotters!

[OrangeXJ]

Looks nice but I don't want to :pee: on your praide but I would take it to a drive shaft place and get it balanced.

[XJ4IV]

Looks nice but I don't want to :pee: on your praide but I would take it to a drive shaft place and get it balanced.

oh I am! but that place in an hours drive from here and I gotta wait till next paycheck!
looks like all thats left is the new brake booster and plumb the lines!!! and MIGHT need rear wheel cylinders

[4.3LXJ]

oh I am! but that place in an hours drive from here and I gotta wait till next paycheck!
looks like all thats left is the new brake booster and plumb the lines!!! and MIGHT need rear wheel cylinders

Might need a new master cylinder with those big brakes too Scott. But good to see it coming together. Then you will get to dial everything in. I am still doing that too :p

[XJ4IV]

Might need a new master cylinder with those big brakes too Scott. But good to see it coming together. Then you will get to dial everything in. I am still doing that too :p

already got it! I bought the E350 setup and when the jeep guys were telling me about it they forgot to mention that a ABS setup booster wouldnt work so I opted for the dual diaphragm in a 95-96 setup this is the final purchase... until I make another one LOL

[4.3LXJ]

Right on Scott

[XJ4IV]

well I went out this evening with an arsenal of fittings and my friends borrowed brake flaring kit... I got everything plumbed up and went to bleed the lines and ONE of them leaks and I cannot get it to seal up right... I THINk its a different kind of flare for that rear line guess I get to spend an hour at the carquest tomorrow trying to match it all up!
I WISH I could just make a splitter valve for the fronts and do the rear directly into the master cylinder! looks like yet ANOTHER setback!!!

[duckcreek]

nice shaft :love0055:

[XJ4IV]

well here is the new 85 E350 master cylinder and new 95 brake booster with dual diaphragm
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG203-2.jpg

I went out today to have another go at tightening the brake lines down and then I noticed that ALL the fittings I had flared were not quite sealed up so I said F it im taking it to the shop!
before:
http://i1133.photobucket.com/albums/m590/XJ4IV/DSC00596.jpg
After:
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG204-1.jpg
I got some MUCH needed cleaning done today

and probably my WILDEST jeep feat yet... loading it on the trailer with NO brakes what so ever! not even emergency brake!

[4.3LXJ]

Uh Scott, someone stole your Jeep :p

[TeXJ]

sell out!

[XJ4IV]

Uh Scott, someone stole your Jeep :p

thats what it feels like... but I know shes in good hands!
still, I felt bad so I went to visit her tonight!
I was so proud when I showed up and my jeep sitting amongst about 20 wranglers and mine was sitting taller than ALL the others... made me feel great!
I had to pick up my shock tabs I had cut out so I can do some more work on

[4.3LXJ]

Just the old man showing the youngsters how it is done.

[Mudderoy]

thats what it feels like... but I know shes in good hands!
still, I felt bad so I went to visit her tonight!
I was so proud when I showed up and my jeep sitting amongst about 20 wranglers and mine was sitting taller than ALL the others... made me feel great!
I had to pick up my shock tabs I had cut out so I can do some more work on

Scott we're going to find out who keeps changing your avatar. The most recent one is hideous. Do you need help changing it? :poke: :rotfl2:

[XJ4IV]

nope thats a representation of the rebirth of my jeep... indian heritage... CHEROKEE indian to be exact!!!

[TeXJ]

I've got Cherokee Engine in me! and I think navajo, different sides of the fam.

[XJ4IV]

I KNOW Ive got cherokee in my blood... if nothing else Ive shared enough blood on my XJ that cherokee is flowing in my veins!!!

[4.3LXJ]

In my case, it is a lot of my blood from busted knuckles on the Cherokee

[XJ4IV]

OK so the build is nearing to an end! today I aws able to get it trail worthy minus the front driveshaft! I need a few tweaks to get her street legal like figure out the emergency brake and add a steering stabilizer... it death wobbled on me today!
I need to adjust the pushrod on the brake booster, I figured that issue out today... the whole time I waasnt hearing the hissing sound was cause the leak was SO BAD that it wasnt even hissing so I made a gasket for that today and WOW she stops great now!
I took her out in the river near my house and I forgot my phone to take pics but I was able to get my first break out of the way... luckily for me its JUST about the cheapest thing to replace!
http://i1133.photobucket.com/albums/m590/XJ4IV/IMG_1803.jpg
dang thing just ripped right in half... guess its time for those metal ones!

[XJ4IV]

if you cant tell thats a valve stem

[4.3LXJ]

A quick flat Scott?

[XJ4IV]

yeah I was only in 2wd cause I still gotta get a front DS and I was just spinning the wheels while in the river on the rock bed and they just ripped it RIGHT off! im thinking I might do the metal upgrades but in thinking about it... the rubber one SHOULD flex I think this one was either worn out and ready to fall off or pure fluke chance

[Mudderoy]

So what was the grinding sound? Did you fix it?

[ironmanandy]

So what was the grinding sound? Did you fix it?

I think it was him thinking.... shhhh I didn't say that lol

[TeXJ]

I think it was him thinking.... shhhh I didn't say that lol

haha

[XJ4IV]

the pinion angled to HIGH... had to shim it down 4 degrees... the yokes were making contact only drove it onto the trailer with it like that . shes all good now!
today I adjusted the brake pushrod so that should be perfect now... tomorrow I gotta get the tire reseated at work and Ill get some more pics of her in her natural habitat

[TeXJ]

WOW dude! Im impressed!

[Mudderoy]

the pinion angled to HIGH... had to shim it down 4 degrees... the yokes were making contact only drove it onto the trailer with it like that . shes all good now!
today I adjusted the brake pushrod so that should be perfect now... tomorrow I gotta get the tire reseated at work and Ill get some more pics of her in her natural habitat

Good. I was concerned about the ring and pinion since you set them up yourself. I've always been told to have a professional do it.

[TeXJ]

Good. I was concerned about the ring and pinion since you set them up yourself. I've always been told to have a professional do it.

Setting up gears isnt that hard, just a few key items that need to be addressed. I had a friend help me set up my gears in my jeep, Scotters was there as well!

They are still doing great. Such an improvement!

[XJ4IV]

mine did great... once you get the pinion shim depth set identical to the OE depth then you just gotta follow factory specs for torque specifications to set the preload... I had the pinions both taken to the shop I used to work at... same guy who did my brake lines
then the only other thing you have to worry about is carrier shim which i got VERY lucky BOTH my axles had no shims on the OE setup which meant the carriers didnt have to get shimmed either!
Pics on the way... I only got a few pics from a backroad here near my house cause massive storm was brewing and I needed to get back home before the storm... I made it in the door and caught a few drops on the shoulders!
Pssshhhhh tony thinks im not a professional.... I get paid to work on cars! LOL

[XJ4IV]

as promised
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone001.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone002.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone003.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone004.jpg.
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone005.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone006.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone007.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone008.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone009.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone010.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone011.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone012.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone013.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone014.jpg
http://i1133.photobucket.com/albums/m590/XJ4IV/JeepsDone015.jpg

[4.3LXJ]

It has been a long time coming ah Scott?

[XJ4IV]

man Ill never do that to myself again ... 6 months with no jeep makes one weak!!!
I wanted to buy another one just so I can drive one!
If I EVER decide to do something big like this I will buy every single item PRIOR to taking the "immobilization" step!

[OrangeXJ]

looking good scott

[Mudderoy]

mine did great... once you get the pinion shim depth set identical to the OE depth then you just gotta follow factory specs for torque specifications to set the preload... I had the pinions both taken to the shop I used to work at... same guy who did my brake lines
then the only other thing you have to worry about is carrier shim which i got VERY lucky BOTH my axles had no shims on the OE setup which meant the carriers didnt have to get shimmed either!
Pics on the way... I only got a few pics from a backroad here near my house cause massive storm was brewing and I needed to get back home before the storm... I made it in the door and caught a few drops on the shoulders!
Pssshhhhh tony thinks im not a professional.... I get paid to work on cars! LOL

{cough} Durango {cough} :D

It's great to see it out and about again. You made a lot of changes, and worked out the bugs. I hope it works well for years now with just some minor maintenance.