88 xj project build

[DRHCHEROKEE88]

Here is what im starting with.

[DRHCHEROKEE88]

Upload is not working right now srry. pics soon. Mods I have going so far are a 6.5 inch IRO long arm kit. 33x12.50x15 goodyear wrangler kevlar mtr's with pro comp 52 series steel rims. Grant challenger steering wheel. Rugged ridge SYE kit.

[XJ Wheeler]

No worries, if ya need help feel free to ask. Sounds like a sweet rig!

[DRHCHEROKEE88]

Pic of the new wheel and the new rear suspension and new rear end mounted in it.
progress!

[DRHCHEROKEE88]

pictures of the front end parts!

[4.3LXJ]

You will love it when you get the front done

[DRHCHEROKEE88]

Well its been an uphill fight so far. Replaced the blown up rear end only to find that its replacement was bent. I was really excited on the new rear end as it was a posi unit. Got the long arm kit on the front and having to build a new front axle due to the old one bieng bent at the c's. So im looking into a ford 8.8 for the rear and i have another dana 30 for the front. After i get those squared away its time to install the sye kit and order a driveline. Also for a late christmas gift i got a new lawrance GPS unit for it! im excited and anxious to get this beast done and test drive.

[DRHCHEROKEE88]

Here is the other hobby i have besides building my XJ. Just wanted to share with you folks.

[4.3LXJ]

Lots of money doing that. I used to live down the street from a guy making tube frames for those in Prescott WA. He didn't sell those cheap. Good thing you are sponsored

[XJ Wheeler]

Very cool! Whats the specs on the Camaro?

[DRHCHEROKEE88]

77 Camaro , weighs 3300 lbs with me in it , Chevy 350 that is .30 over with flat top keith black pistons , isky racing .511 lift cam , vortec heads with 2.02 , 1.60 one piece swirl polished stainless steel valves , a demon 525cfm 2 barrell carb. Rear end is a speedway engineering full floater 9in with a 6.50 gear. Four speed muncie trans. Class is called street stock and is semi budget friendly haha. Lots of fun and im hoping my XJ will be also.

[XJ Wheeler]

77 Camaro , weighs 3300 lbs with me in it , Chevy 350 that is .30 over with flat top keith black pistons , isky racing .511 lift cam , vortec heads with 2.02 , 1.60 one piece swirl polished stainless steel valves , a demon 525cfm 2 barrell carb. Rear end is a speedway engineering full floater 9in with a 6.50 gear. Four speed muncie trans. Class is called street stock and is semi budget friendly haha. Lots of fun and im hoping my XJ will be also.

Very nice! 3300# that's an achievement in itself. :D Sounds like a blast.

[DRHCHEROKEE88]

Is there any way to bend the Dana 35 back straight without comprimising its strength? Im thinking get it bent straight and sleeve or truss to add stregth. Any ideas suggestions appreciated.

[4.3LXJ]

D35 rear or D30 front. It is usually the fronts that take a beating and bend

[DRHCHEROKEE88]

D35 rear or D30 front. It is usually the fronts that take a beating and bend

The d30 was bent severly and had to replace also. The original d35 rear end had a blown ring and pinon so i acquired another d35 from a donor cherokee , i was excited because this d35 has the factory limited slip unit in it. However after installation it is clear the rear end is bowed down in the middle as if it were jumped or something. What need to know if it is ok to bend it back and whats the best way to do it either heat or cold?

[4.3LXJ]

Yes, it can be bent back. An I beam, two chains and a hydraulic jack would do it. These have a notoriously weak center casting that is known to flex too much anyway. Trussing would help a lot and removing the c clips and converting to the one piece axle bearings would be an upgrade too

[DRHCHEROKEE88]

A picture of the chrysler 8.25 rear end for my 88xj. Coming soon a 29 spline transformation involving Ten alloy axles and a lock rite locker and 4.56 gears

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[DRHCHEROKEE88]

Cleaned the gummed up throttle body today. Also changed plugs and wires and cap and rotor. Gave it a smoother idle.

Put on iron rock offroad coil spring spacers also. To remove stock bumpstop use a pipe wrench.

Also installed the chrysler 8.25 rear end. And adjusted rear leafs so the jeep sat more level. To take pressure off of leafs jack the body up on the side your working on until the bolt taps out smoothly. If not it is under a load and will bind and be a royal pain.

3354

3355

3356

3357

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[DRHCHEROKEE88]

Here is the final stance once all suspension mods were added.



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[DRHCHEROKEE88]

Just placed a order for axle stuff. Going with 4.88s.

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[Mudderoy]

Just placed a order for axle stuff. Going with 4.88s.

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What are you going to stick those 29 spline axles in? They'll fit the pre 97 C8.25, but the carrier is 27 spline, at least that's what I'm remembering. Someone correct me.

[DRHCHEROKEE88]

You are right bout the carrier. Pre 97 is 27 spline from the factory. After that stock 29 spline. I purchased a 29 spline carrier and the housing and everything else is the same. I believe the seals are different also. A 27 spline axle shaft diameter is 1.19 and a 29 spline is 1.21 . Someone please correct me if im wrong.


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[Mudderoy]

You are right bout the carrier. Pre 97 is 27 spline from the factory. After that stock 29 spline. I purchased a 29 spline carrier and the housing and everything else is the same. I believe the seals are different also. A 27 spline axle shaft diameter is 1.19 and a 29 spline is 1.21 . Someone please correct me if im wrong.


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A good peice of info.
Axles

Front Axles
Dana 30 high pinion - reverse cut - 27 spline, 1.16" diameter shafts, 7.13" ring gear - used 84-99 (some axles through 91 are vacuum disconnect, 92+ are non-disconnect, 89-95 with ABS have 5-297x u-joints, all 95+ have 5-297x u-joints, all others have 5-260x u-joints)

Dana 30 low pinion - standard cut - 27 spline, 1.16" diameter shafts, 7.13" ring gear, 5-297x u-joints - used 00-01

Rear Axles
Rear Axle pics including non stock ford 8.8 and 9" and D60- http://memimage.cardomain.net/member...7_182_full.jpg
(Note on Dana 35 axles sometimes referred to as Dana 35C - The "C" does not stand for c-clip. It stands for "custom" meaning it came from Dana unfinished.)
(Note on 8.25 axles - none of these axles were used on XJs with ABS brakes. If you have ABS, you have the Dana 35. Without ABS you could have either axle. 8.25 axles are c-clip)

Dana 35 non c-clip - 27 spline, 1.18" diameter shafts, 7.58" ring gear, 2.62" axle tube - used 84-89
Dana 35 c-clip - 27 spline, 1.18" diameter shafts, 7.58" ring gear, 2.62" axle tube - used 90-01
Chrysler 8.25 - 27 spline, 1.17" diameter shafts, 8.25" ring gear, 3" axle tube - used 91-96
Chrysler 8.25 - 29 spline, 1.21" diameter shafts, 8.25" ring gear, 3" axle tube - used 97-01
Dana 44 non c-clip - 30 spline, 1.31" diameter shafts, 8.5" ring gear, 2.75" axle tube - used 87-89 on some(not all) XJs equipped with towing package.

Gearing

3.07 - used with 4.0L engine / manual transmission
3.31 - only available on older (pre87?) 2 door XJs with "Fuel Economy" package
3.55 - used with 4.0L engine / automatic transmission
3.73 - found in some XJs with the towing package
4.10 - used with 2.5L engine usually, and older XJs with the "Off-Highway Vehicle" package.
4.56 - rare but can be found on some older (~ 89 ~) models with 2.5L engine and auto transmission

:link: (http://www.naxja.org/forum/showpost.php?p=244556400&postcount=13)

Hmmm no bearing info though...

[DRHCHEROKEE88]

Here is a little side note when doing re gear on the Chrysler 8.25 axle. I went with the 4.88 usa standard gear set and also had to order a YUKON notched crosspin. Thats one thing i did not know and it held the axle up for a few days so hopefully you can avoid this with your build and have it ready. The quick fix is to shave some ring gear teeth but I was not going to take that route.