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Rlpetty43
08-24-2014, 10:11 AM
here is what I am slowly working I started this upgrade last November 2013 Thanksgiving weekend with a trip to LKQ pick a part in OKC during one their 50% off sales where I picked a HP D-30 from a 99 XJ which I removed the stock knuckles from and then proceeded to a WJ with akeebono brakes which I Pulled the knuckles and brakes calipers from which appeared to have been replace recently before it found its way to the salvage yard. I then somewhat mocked my gathered up parts to resemble a complete axle assembly. While there I also found an explorer with a 4.10 gear 8.8. Since I had core axle with me I got the pair for less than 150 bucks.

http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/1451958_10201221360678628_1573355398_n_zpsdbf28954 .jpg

Now, first thing I did was sell the 8.8 for 250 bucks which just about paid for the adventure. I didn’t need the 8.8 because I already have one in my XJ. here is a picture of it from when I was swapping it in 2012.

http://i1128.photobucket.com/albums/m498/rlpetty43/ford%2088%20rear%20end/2012-09-15174332-1.jpg

Rlpetty43
08-24-2014, 10:24 AM
next step was prepping the d-30 axle housing for what I had instore for it.
http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/2014-03-22_20-21-29_824_zpsa6433de4.jpg (http://s1128.photobucket.com/user/rlpetty43/media/XJ%20progress/2014-03-22_20-21-29_824_zpsa6433de4.jpg.html)
Sandblasted the knuckles, and caliper brackets, the caliper brackets got painted at this point also noticed the JKS track bar mount and the TNT taper inserts, which I ended up going another route on the rod ends. (More on this later).http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/2014-03-22_13-35-36_975_zps0d33b5e1.jpg (http://s1128.photobucket.com/user/rlpetty43/media/XJ%20progress/2014-03-22_13-35-36_975_zps0d33b5e1.jpg.html)

Rlpetty43
08-24-2014, 10:30 AM
now for the new stuff,
JKS hub adapters
http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/2013-12-31_05-38-19_872_zps1kzhyig9.jpg
Artec truss, currie Johnny joints, and artec knuckle gussetts
http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/2014-03-20_18-31-20_336_zps3e61c03b.jpg

4.3LXJ
08-24-2014, 10:31 AM
Nice way to pay for the project

Rlpetty43
08-24-2014, 10:42 AM
Now the steering when I got to this point my first intentions was to use JKS tie rod and drag link setup that uses the WJ rod ends which is why I bought the TNT jeep taper inserts. However back then it seemed JKS was getting out of making them so back to the drawing board I went. So what I ended up with instead was with the ruff stuff JK one ton tie rod kit and another length of their 1.25x.250 DOM and the needed rod ends for the drag link along with the necessary rod end inserts

http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/1396568955062_zps2f61878a.jpg

Rlpetty43
08-24-2014, 10:45 AM
thanks, if you have a LKQ pick a part lot near a I reccomend them a bunch, its sad I can drive to OKC 75 miles one way and buy my parts for less than my local salvage yards including he cost of fuel.

Rlpetty43
08-24-2014, 11:05 AM
After a couple trips to my buddies house for welding (I am far from a welder) and some cleaning and painting here is where I am at.

http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/1408896013069_zpsef798f01.jpg

the main things lack on it is rotors, wheel bearing hubs, track bar, and locker. hoperfully in a few weeks I will pick up a set of rotors from Ironrock.

Mudderoy
08-24-2014, 11:41 AM
Almost makes me want to go work on something. :popcorn:

Rlpetty43
08-24-2014, 11:56 AM
Almost makes me want to go work on something. :popcorn:

Me too it has been on pause and taking way longer than I thought hopefully I can get back on track

XJ Wheeler
08-24-2014, 04:58 PM
Nice work! I contemplated the 8.8 swap but figured I am not going bigger than 33s for now. That axle is gonna be sweet! Keep us updated.

Rlpetty43
08-30-2014, 02:55 PM
Today I went to my local autozone with passenger knuckle in hand to try out different wheel bearings and rotors. Since I Have a few different threads and different folks using 2001 xj unit bearings (Im am not sure what differences there are or not) that is what I started out with, after test fiting wj, explorer, and crown vic rotors on the counter it appears the crown vic is going out fine for me. so I picked up unit bearing today and will pick up the rest as I go. so I am now one more part closer :)

Rlpetty43
09-06-2014, 03:37 PM
I made a play change and went with sport track rotors, last weekend I took advantage of AutoZone’s Labor Day sale and purchased unit bearings, rotors, brake pads, and caliper pins which all arrived Thursday. Today I broke out the grinder and ground down the wheel bearings to fit the sport trac rotors. I test fitted it all and looks fine. I also pulled one of my rims off the XJ to make sure I could stay with 15 inch rims and they fit as well lucky me!! however my backspacing is 3.75" and the caliper makes very slight contact with the rim I’m sure that the caliper would self clearance and be fine but I believe I will go with a 3.5" backspacing since I already have two bent rims it wouldn’t take much more to just get 4 new rims with 3.5” backspacing.
http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/1410016347991_zpsa0d8cc50.jpg (http://s1128.photobucket.com/user/rlpetty43/media/XJ%20progress/1410016347991_zpsa0d8cc50.jpg.html)
http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/1410016014928_zps80397e9d.jpg (http://s1128.photobucket.com/user/rlpetty43/media/XJ%20progress/1410016014928_zps80397e9d.jpg.html)

bluedragon436
09-06-2014, 04:52 PM
Looks like it's coming along nicely... You should keep the part #'s that you use, along with what OEM JY parts you are running, to do up a list for folks that think about doing the same setup.. I know once I pick up another Jeep to build, I plan on doing something similar with an HP30, but have seen many random folks input on what you can run and what will or won't work... so would be nice to see from someone who can say what does in fact work.. Look forward to seeing progress on this build!!

Rlpetty43
09-06-2014, 05:52 PM
Looks like it's coming along nicely... You should keep the part #'s that you use, along with what OEM JY parts you are running, to do up a list for folks that think about doing the same setup.. I know once I pick up another Jeep to build, I plan on doing something similar with an HP30, but have seen many random folks input on what you can run and what will or won't work... so would be nice to see from someone who can say what does in fact work.. Look forward to seeing progress on this build!!

Thank You, I’ll be glad to do a parts list, I know 3 or 4 other personally that have done WJ knuckle swaps and there is more than one way to go when it comes to unit bearing/rotor/caliper combos most of the others went with the "Teeve calipers" I really wanted the "Akeebono calipers" that is why I am doing so much test fitting. I still have a long ways to go but I do have a plan hopefully I can keep up the progress. I really need to get this done the current front axle is about completely worn out when it comes to steering and the brakes, my tires are also about shot. I had to make sure 15 inch rims would work with this setup because I have seen a few folks that had to with larger rims. As far what I do next I am unsure take care of the worn out tires or finish he axle first. I can create a list of parts I have used so far and post it tomorrow.

bluedragon436
09-06-2014, 05:55 PM
I can't remember from when I was doing the research which were the more preferred calipers to pick up.. Can't remember if there was a reason stated for why they preferred one over the other though...

Rlpetty43
09-06-2014, 06:07 PM
From what I know the "Teeves calipers" were replaced by the "akeebono" on the WJs the reason most say is the "teeves" warp rotors. there is a couple ways to tell them apart one "akeebono calipers" will say "akeebono" on them also the "akeebono" calipers mounting bracket is removable from the knuckle and the teeves bracket is made to the knuckle.

bluedragon436
09-06-2014, 06:20 PM
Yeah I was thinking the Akeebono's were the ones that were desirable for doing this kind of build up... or even more so if you were just picking up a WJ in the first place!! But def look forward to seeing this D30 build completed..

Rlpetty43
09-07-2014, 12:21 PM
My WJ knuckle swap parts list
1. One high pinion Dana 30 axle from a 1999 XJ

2. One set of WJ akeebono knuckles complete with caliper brackets and calipers (I lucked out the WJ I found in the salvage yard appeared to have had the calipers replaced recently to finding the way to the scrap pile).

3. One Artec HP Dana 30 truss kit (XJ3003) complete with Currie Johnny joints.

4. One set of Artec inner c Gussets (TJ3010)

5. Two JKS steering knuckle flange spacer (OGS 930)

6. One JKS Track bar relocation Bracket (OGS 920) note: while creating this list I discovered Artec now has a track bar relocation bracket that looks to be a option If I was to do this again I may would look in to using theirs instead.

7. One Ruffstuff Specialties JK tie rod kit (JKTIEROD)

8. 30 inches of 1.5 x .250 DOM from Ruffstuff Specialties (drag link)

9. One Ruffstuff Specialties TRE, Standard, (TK234) pitman arm link complete with weld in bung and nut

10. One Ruffstuff Specialties TRE, Offset , Passenger side right hand thread (TK23434R) Knuckle Link side of draglink complete with weld in bung and nut

11. Four Ruffstuff Specialties Tapered knuckle inserts (INSTEER)

12. Two Master Pro greaseable upper ball joints *Oriellys* (k3134) note XJ and WJ upper ball joints are the same ball joint so to make life simple one can tell the counter guy one needs upper and lower ball joints for a WJ.

13. Two Master Pro greaseable lower ball joints *Oriellys* (k3185) my research and from talking to friends have done this swap WJ lower ball joints is the way to go. * Reason I bought theses from Oriellys is they had both upper and lowers hat were greasable and none adjustable. I won’t know for certain this is a winning combo till it is on the alignment rack.

14. Two Dura last hub assembly bearings (DL513158) 1999 XJ I haven’t done the research to how many different unit bearing and where used there is all I can say these are different than what my 91 XJ d-30 used.

15. Two Dura last rotors (54097) 2001 ford sport track.

16. One set of Dura last brake pads (mkd945)

The above list are the Items I have already bought and so far all seems well this project is not yet rolling and Items used may change the following are items I need to complete my swap that I plan on using which could change if fit and function issues arise

1. Rusty's Over The Knuckle - Adjustable Front HD Track Bar & Frame Mount XJ,ZJ (RC-TBOTK-UV)

2. Eaton Elocker

3. G2 ring and pinion 4.88
I am probably forgetting some items which I will add and revise as I go.

4.3LXJ
09-07-2014, 12:25 PM
That seems fairly complete. Lots of good stuff there

Rlpetty43
11-23-2014, 03:16 PM
well Finally bought the locker and all the install stuff and took it to my friends and set up the gears and locker it will not be long now it will be siting under my jeep. Which is a very good thing because my current Sway bar is done during the road trip to my friends the track bar came extremly close to failing the axle side bushing is completly done and the mounting hole on the axle is wallered out now.

4.3LXJ
11-23-2014, 07:03 PM
I have a fix in the tech section for that

Rlpetty43
11-24-2014, 07:13 AM
Hopefully in couple weeks I will be able to put my new axle in and not mess much with this one.

Rlpetty43
12-02-2014, 09:43 AM
well Finally bought the locker and all the install stuff and took it to my friends and set up the gears and locker it will not be long now it will be siting under my jeep. Which is a very good thing because my current Sway bar is done during the road trip to my friends the track bar came extremly close to failing the axle side bushing is completly done and the mounting hole on the axle is wallered out now.

just noticed my error I meant track bar not sway bar however curently my sway bar has been disconected and has been forever, once the new axle is in place I will come up wit some sort of quick disconects for the sway bar.

Rlpetty43
12-02-2014, 09:55 AM
over the weekend I took advantage of all the sales going on I ordered the rusty's OTK track bar, the tie rod ends for my drag link (first time around I orderd them opposite of what I needed), A diff cover for my 8.8 (TREs and diff cover from ruffstuff), rough country stainless steel braided brake lines, factory ten axle tube seals, and fluids and brake hardware. So in theory I should have everything to finish up my swap. I will try to remember to take pics as I go, also while I have the axle out I have a block heater to install. My plan is to begin on the dec7th with disasembly and have i ready to put the axle in on the 13th.

Rlpetty43
01-03-2015, 11:35 AM
Well it's finally under he jeep all it let is to bleed the brakes, fill the diff, wire up the locker, powder coat the steering links, and a alignment I think LOL, heads up the sport trac rotors were slightly to deep and rubbed the inside of the caliper mount it was pretty easy to fix a washer on each lug behind the rotor did the trick.
http://i1128.photobucket.com/albums/m498/rlpetty43/XJ%20progress/10888967_10203559235604040_7901808897729513555_n_z ps0cef0889.jpg

bluedragon436
01-04-2015, 05:51 AM
That is a nice clean axle setup you got going on there... Wish I had the knowledge and money to spare right now to do a similar build up for my 97.. One day I'll have to make sure and reference back to this thread though, especially with that buildup listing above when I do a refresh/rebuild on the axles..

4.3LXJ
01-04-2015, 10:25 AM
Looks real nice. I like that over the knuckle set up on that conversion

bluedragon436
01-05-2015, 01:47 AM
Looks real nice. I like that over the knuckle set up on that conversion

That is def a nice beefy OTK setup... I'm hoping my IRO OTK comes out looking somewhat close to that.. but I know it won't be quite the same.. Man the more I see pics of this setup the more I wish I had the money to do the full conversion of brakes and everything, including that steering setup..

4.3LXJ
01-05-2015, 10:44 AM
James, if you get wrecking yard parts on that setup, the stock WJ tie rod is much beefier than what we would have with a ZJ tie rod. Just using the stock drag link and flipping the tie rod is a big improvement

Rlpetty43
01-09-2015, 08:13 AM
A little further update once everything was together and set with the wheels on I had to clearance the tie rod ends more that I care for to clear the rims and wheel weights when turning. I am going to try some 5/16 wheel spacers and see if I like that better. I will continue to add notes here and there as I tweak and tune for my reference and for others.

cantab27
01-20-2015, 10:50 PM
did the 91 have abs .......having problems with same sort of set up in a 99 with abs ....

4.3LXJ
01-20-2015, 11:29 PM
The WJ giving you problems mate?

cantab27
01-21-2015, 02:47 AM
no mates xj with same mod done .....abs giving problems

4.3LXJ
01-21-2015, 11:27 AM
Early XJ, as in Renix years?

msmoorenburg
01-21-2015, 12:06 PM
no mates xj with same mod done .....abs giving problems

pull the big ABS fuses :smiley-taunt002: problem solved and no dash light :smiley-chores003:

cantab27
01-21-2015, 06:52 PM
lol that's what I said matt.......will do another thread on problem

Rlpetty43
01-25-2015, 02:44 PM
did the 91 have abs .......having problems with same sort of set up in a 99 with abs ....

no ABS on mine brakes wok really well although I still have the original proportioning valve so they do seem to be a bit bias to the rear also I still have the original power booster and master cylinder so someday Ill swap those but still as it is the brakes are way stronger.

Rlpetty43
04-20-2015, 08:15 AM
learned on my first trip with the 35s I had some rubbing on the rear quarters, so the last couple of weekends I trimmed and folded in the quarters below the taillights and started building my rear bumper

Rlpetty43
07-06-2015, 11:13 AM
over the holiday I started building my rear bumper I will post pics and such later when I am a little farther along so far I have one bumper mount tacked together

Rlpetty43
12-02-2015, 08:12 AM
last night we made some progress on my rear bumper build, no pics yet also still more work to do to that, recently I have also been working on my auxiliary hazard lights I have had led strobes on the back and sides for quite sometime now but recently started putting the front facing ones on, also no pics of that yet also I installed a block heater over thanksgiving which I finally used last night. the block heater work great the water temp was around 110 this morning and quickly defrosted the windshield and somewhat warm heat right off the get go.

Rlpetty43
12-07-2015, 08:14 AM
last night we made some progress on my rear bumper build, no pics yet also still more work to do to that, recently I have also been working on my auxiliary hazard lights I have had led strobes on the back and sides for quite sometime now but recently started putting the front facing ones on, also no pics of that yet also I installed a block heater over thanksgiving which I finally used last night. the block heater work great the water temp was around 110 this morning and quickly defrosted the windshield and somewhat warm heat right off the get go.

long story short the block heater gave me trouble it would not stay seated into the block so after the second time of popping out I removed it and put a freeze plug back.