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Thread: XJ Dana 35 to Ford 8.8 Swap

  1. #31
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    Re: XJ Dana 35 to Ford 8.8 Swap

    I gained about 3/4" with the bigger axle tube diameter and the thicker brackets. I lost about 1/2" of ground clearance at the housing though. I guess I will just have to get some bigger tires now!

    Sent from my XT1526 using Tapatalk

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  2. #32
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Nice work!

    Now, when you are hung up on rock and someone yells 8 8, you'll know what your stuck on!
    Get Down With the Sickness!

  3. #33
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    XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by Bugs View Post
    Nice work!

    Now, when you are hung up on rock and someone yells 8 8, you'll know what your stuck on!
    At least I know I won't break a shaft or ring and and pinion set. I just need to save up for a Detroit locker in there. Let me know if you see one around


    Sent from my iPhone using Tapatalk

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  4. #34
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    Re: XJ Dana 35 to Ford 8.8 Swap

    I finally measured my track width front and rear and proved that the 8.8 is an inch narrower.
    Front: 74.5"
    Rear: 73.5"

    I might add 1/2" wheel spacers in the future when I have some extra money laying around and time to do it. The only problem is that no one makes the exact length needed so I would have to cut them to length. Its really not noticeable without busting out the tape measure.
    I have been very pleased with the swap so far and the only "issue" I am having is up travel on the shocks. I either need shorter shocks or more lift....... I am thinking shackle relocation boxes and adjustable shackles and some spacers in the front to even it out.
    The only thing left for me to do is regear the front axle to 4.10's. I have the gears and carrier but need to buy the install kit. I am saving up for it and will get it by the end of the month. Then I will have to set up the gears....... That will be interesting. I can't wait to get back my 4 wheel drive and get on the trails!

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  5. #35
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    Re: XJ Dana 35 to Ford 8.8 Swap

    I like to build a cross member and triangulated the shocks inward /\

    Gets best travel out of a short shock. Also stiffens the unibody up.

    Do a c-clip eliminator kit and get the width and way better bearings
    LetzRoll Offroad racing 4493
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  6. #36
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by jpcrawleram View Post
    I like to build a cross member and triangulated the shocks inward /\

    Gets best travel out of a short shock. Also stiffens the unibody up.

    Do a c-clip eliminator kit and get the width and way better bearings
    I would like to do a c-clip eliminator kit but need to save up first.


    Sent from my iPhone using Tapatalk

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  7. #37
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Here is a short video I made so you can see the final product.
    https://www.youtube.com/watch?v=1YEvykfADWM

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  8. #38
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Nice looking rig!
    Get Down With the Sickness!

  9. #39
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    Re: XJ Dana 35 to Ford 8.8 Swap

    One thing I forgot to address is that the 8.8 housing is not centered. One shaft is a few inches longer than the other. This moves the drive shaft over about 2 inches from a stock axle on an XJ. The drive shaft is very close to the muffler but never makes contact through the suspension cycle. I flexed the rear in both directions and never touched. I will have to add a picture when I think about it again during the day.

    Sent from my XT1094 using Tapatalk

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  10. #40
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by Pinoy59 View Post
    One thing I forgot to address is that the 8.8 housing is not centered. One shaft is a few inches longer than the other. This moves the drive shaft over about 2 inches from a stock axle on an XJ. The drive shaft is very close to the muffler but never makes contact through the suspension cycle. I flexed the rear in both directions and never touched. I will have to add a picture when I think about it again during the day.

    Sent from my XT1094 using Tapatalk
    Same on my TJ, but never a problem.
    Get Down With the Sickness!

  11. #41
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Nice work on that axle!
    Really a great truss setup!
    Im back to the drawing board
    STAY TUNED!

  12. #42
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Here is a picture of the shafts. You can see that the driver side is longer than the passenger side by a couple inches.



    Sent from my XT1094 using Tapatalk

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  13. #43
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Just an update now that I have been running this set up for 2 years now. Everything is working great. I installed 4.10 gears (with a lock right) up front and a Detroit locker in the rear. The traction is amazing, but for some reason when installing the Detroit, the cross pin (notched) was too thick so I had to shave down the shafts a little bit to get it to fit.When I removed the carrier, I noticed that one of the bearings had a lot of pitting on it, so I am glad that I fixed it before it became a problem. No problems since the install. I still haven't gotten shorter shocks but plan on adding 2" of lift pretty soon. A while back I got a ZJ (with rear disks) Proportioning valve and yesterday I finally swapped the internals. I think it brakes better now. The front doesn't dive down as much as it used to and it will actually lock up the rear when I really get on the brakes.
    I have done some decent trails now and I haven't been caught up on my diff yet, but people keep telling me I will. I plan on going to 35's once I can afford new tires and chromoly shafts up front. Its a slow process but the Jeep is coming along nicely.
    If there was one thing I could change, it would be where I put the vent tube. I put in on the center line on the front of the axle tube because the truss was in the way on top of the axle. I fear one day it will get caught on the perfectly shaped rock, but so far I have been lucky. It is fairly close to the tire which has kept it out of harms way, for now.
    I have had a little bit of contact of the exhaust hanger on the drive line as the exhaust bounces around but only rubbed the rust off a little. Not enough to worry about.
    I still haven't gotten my e-brake to work. I don't know if its due to the self adjusters of something else. When tightening the cables they don't seem to have the same amount of tension on them so the equalizer is not straight. I don't use my e-brake very often because its an automatic so I haven't made it a priority. Although if anyone with drum brake knowledge wants to look at them, I wouldn't be opposed.
    Some day I would like to remove the ABS pump and reroute the hard lines. I don't really feel comfortable doing this myself so I will probably have a shop do it if I ever get around to it. It wouldn't be a bad place to put an air pump when I free up the space.
    The last thing I would like to do, but haven't gotten around to yet is securing the hard lines to the axle. They are just zip tied in place between the mounting point on the axle and the brake calipers. A few people have given me some dirty looks over this, but I don't think it matter all that much. If i had a welder, I would but a couple of tabs on to hold the lines in place, but I don't have one...
    All in all, everything works well and I am very pleased. I love not having the Dana 35 any more and I learned a lot in this process.

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

  14. #44
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by Pinoy59 View Post
    Some day I would like to remove the ABS pump and reroute the hard lines. I don't really feel comfortable doing this myself so I will probably have a shop do it if I ever get around to it.
    What's this ABS stuff you refer to?
    '93 YJ, 4.0, NV4500, Atlas, 35s
    '17 WK2, 5.7, ZF8HP70, NV245, 31s

  15. #45
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by TreeKiller View Post
    What's this ABS stuff you refer to?
    Its the plague of the dana 35. All XJ's with ABS had the 35. I pulled the fuses and the relay so its just dead weight.

    97 Cherokee with NP242 T-Case/skid plate, front/rear skid plates, tow package, RC 4.5" LA lift, locked f/r, trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws on 15x10 rims. Custom rock sliders, fender flares, winch bumper & 9k lumen light bar.

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