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Thread: XJ Dana 35 to Ford 8.8 Swap

  1. #16
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Once everything was tacked in place I put it under the Jeep to make sure everything fit well.



    I sold my Dana 35 for $150. I am glad to have that gone!




    I got everything welded on and painted. I am just waiting for it to fully dry before I install it.




    Also, here is the drive line angle at full droop. It's not bad at all.




    I still need to drill a hole for the vent that will hold the soft line to the axle. Then I will be able to get it all together and back on the road!

    Sent from my XT1526 using Tapatalk
    Last edited by Pinoy59; 05-18-2016 at 08:47 AM.

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

  2. #17
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Good write up. Not sure if your interested or in the market but I have a friend pulling a freshly rebuilt with advanced adapters sye 231 from a 98xj
    New #6312 buggy under way .. -Kaos Krawlers- LetzRoll Offroad Racing #. JM Rigging Supply, Catsonly Muffler

  3. #18
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by frontier13 View Post
    Good write up. Not sure if your interested or in the market but I have a friend pulling a freshly rebuilt with advanced adapters sye 231 from a 98xj
    PM sent. I have the same yoke he has and mine is in a YJ. Talk about a short driveline!

    If Pinoy59 is not interested in it, I'd like a shot at it.
    Non-College Educated Working Class White Deplorable....

  4. #19
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by frontier13 View Post
    Good write up. Not sure if your interested or in the market but I have a friend pulling a freshly rebuilt with advanced adapters sye 231 from a 98xj
    I currently have the 242. What is he asking?

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

  5. #20
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    Re: XJ Dana 35 to Ford 8.8 Swap

    350.. It has 3 runs in it from fresh rebuild with advanced adapters 32 spline sye.
    New #6312 buggy under way .. -Kaos Krawlers- LetzRoll Offroad Racing #. JM Rigging Supply, Catsonly Muffler

  6. #21
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by frontier13 View Post
    350.. It has 3 runs in it from fresh rebuild with advanced adapters 32 spline sye.
    Its not in my budget right now. I will pass and let OTR-93YJ have it. Thank you!

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

  7. #22
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Let me know when it's pulled. Not sure I can pay that much, but we'll see.
    Non-College Educated Working Class White Deplorable....

  8. #23
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    Re: XJ Dana 35 to Ford 8.8 Swap

    I started to put the axle under the Jeep but noticed a problem right away. The u-bolt plates had a hole in the center where the retaining bolt and nut fit but since I have different leaf packs the nut was bigger and would not fit through the hole. The hole needed to be enlarged to about 3/4" to fit. I have a 25/32" drill bit that I used to install my lift kit so I planned to use that. I put the plates on a drill press but the bit got dull so fast it was like trying to drill through unobtainium. After a lot of cutting oil and a few smaller bits, I managed to get them to fit over the nut.
    Then I ran into another problem. The truss sits right on the center of the axle tube, and the space between the perch and the truss was not big enough for the u-bolts to fit through. I had to cut off some of the truss on both ends to get them to fit.
    Once I got the nuts torqued down I tried to put the bolts through the shock mounts, but the u-bolt made it impossible to get it through the hole. So I had to take the u-bolts back off and put the shocks on first.
    I got the axle shafts back in and the cross pin as well but found that the spider gears had moved while the pin was out so that the pin wouldn't go through initially. Luckily that's a pretty easy fix. I got the brake rotors and calipers on and just need to get the hard lines figured out.
    I did learn that the e-brake cables from a ZJ will not work on a 97+ XJ because the ZJ cables mount in the center and are the same length while the XJ cables mount on the drivers side and one is much longer than the other. East coast gear supply has a set but they cost $100 + shipping. I will most likely have to spend the money since no one makes them.
    The only thing left to do is drill the hole for the vent and mount the soft line to the axle and connect the hard lines to it.

    Here is a picture of the current state.


    Sent from my XT1526 using Tapatalk
    Last edited by Pinoy59; 05-23-2016 at 01:15 PM.

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

  9. #24
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    Re: XJ Dana 35 to Ford 8.8 Swap

    If you have the cables for the parking break that came with the 8.8 you can cut the end tab off of your cables and slide them into the cables from your jeep. Measure and use a cable lock for the end or if you look through my old posts I did a review on a place in town that builds cables. He crimped new ends on my cables for like 10 bucks cash.

  10. #25
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Looking good!
    Non-College Educated Working Class White Deplorable....

  11. #26
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Quote Originally Posted by mcen View Post
    If you have the cables for the parking break that came with the 8.8 you can cut the end tab off of your cables and slide them into the cables from your jeep. Measure and use a cable lock for the end or if you look through my old posts I did a review on a place in town that builds cables. He crimped new ends on my cables for like 10 bucks cash.
    I don't live in AZ anymore, sadly That would work for the one that is too long but not for the one that is too short. I just paid $115.74 for a set from ECGS.

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

  12. #27
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Bummer

  13. #28
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Just the brake lines left to finish.
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    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, front locker,trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws with 15x10 rims. Custom rock sliders, rugged ridge fender flares, & 9k lumen light bar.

  14. #29
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    Re: XJ Dana 35 to Ford 8.8 Swap

    The brake lines are giving me more trouble than I had anticipated. The fittings on the hard lines are not holding the flared part on to the soft lines. I am not sure if I should cut the end of the fitting or what...... I stripped the threads on one of the soft lines so I will have to buy another one. Anyone have any advice?

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

  15. #30
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    Re: XJ Dana 35 to Ford 8.8 Swap

    Finally back on the road!




    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, front locker,trussed 8.8,410s, dual steering stabilizer on 33x12.5 mud claws with 15x10 rims. Custom rock sliders, rugged ridge fender flares, & 9k lumen light bar.

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