[fphipps]

so i have seen people put ford 8.8 rear axles on thier xjs and i was wondering how hard it is to do that?im looking for a better axle to replace my Dana 35.....would it be easier to just a C8.25?

[dcorn]

You'll have to cut off whatever spring and shock brackets are on the 8.8 and weld on new ones specifically for the Jeep. Ruff Stuff specialties makes an entire kit to do it, so it shouldn't be too hard as long as you have a grinder and a welder, or know someone who does.

The 8.8 will be stronger than the 8.25 and has much more aftermarket support due to it being in the Mustang and many other Ford vehicles.


So where are you in MD?

[fphipps]

ohp then thats out of the question lol...dont know how to weld nor do i know anyone who does and dont have any type of grinder besides the cutting wheel for my little dremel

im in columbia/howard county....pretty much in the middle of the state

[_Trucker]

Originally Posted by dcorn

You'll have to cut off whatever spring and shock brackets are on the 8.8 and weld on new ones specifically for the Jeep. Ruff Stuff specialties makes an entire kit to do it, so it shouldn't be too hard as long as you have a grinder and a welder, or know someone who does.

The 8.8 will be stronger than the 8.25 and has much more aftermarket support due to it being in the Mustang and many other Ford vehicles.


So where are you in MD?

how much stronger than an 8.25..i have a buddy that will give me his 8.8 out of his mustang for $50(alot cheaper than the portal teks my wife won't let me buy..)

[XJLI]

Originally Posted by trucker1

how much stronger than an 8.25..i have a buddy that will give me his 8.8 out of his mustang for $50(alot cheaper than the portal teks my wife won't let me buy..)

a lot. but that mustang 8.8 is probably 27 spline aka worthless.

[_Trucker]

Originally Posted by XJLI

a lot. but that mustang 8.8 is probably 27 spline aka worthless.

i'll find out..it's out of a 67' stang.

[XJLI]

Originally Posted by trucker1

i'll find out..it's out of a 67' stang.

thats a ford 8" not an 8.8

[_Trucker]

Originally Posted by XJLI

thats a ford 8" not an 8.8

your right ...i just got off the phone with him...will an 8" work?

[Keagan27]

It's very easy to find one out of a 95 and up exploder. I got mine for 150 at a you pull it yard. Here is some useful info on the 8.8 that I got of another forum.





Here is a guide for the purchase and build-up of the Ford 8.8 rear axle and its compatability and performance in a Wrangler or Cherokee.
I did a little scrounging around on Jeeps Unlimited and came up with some questions asked and answers given along with some of our experiences. Below there are many links to build-ups and all kinds of info.

If there are things i missed or mistakes please post a correction and i will change it or add more info to the first post.

There are many different variations of the Ford 8.8 axle. One of them is best suited for the use in a Jeep and that would be the Explorer (or Mountaineer) 31 spline 8.8. If you have found one off a Aerostar, Mustang, F-150 etc, you should really pass it up and look for a Explorer axle if you wish to retain a similar track width on your Wrangler. Trying to start your build-up with the wrong axle will be frustrating and expensive although you may have picked it up for cheap in the beginning.

Ford 8.8 assembly specs:
Cover bolt 28-38 ft.lbs.
Pinion bearing preload 16-29 in.lbs.
Pinion bearing preload 8-14 in.lbs (used)
Ring gear backlash .008-.015
Ring gear bolt to case 70-85 ft.lbs
Side bearing caps 70-85 ft.lbs.


Explorer 8.8 Measurements:
Weight (complete assembly w/ brakes etc.): 174 lb.
O.D. of tubes: 3.250".
Tube thickness: .250" (some are .188”!)
Ring gear diameter: 8.800".
Ring gear bolts: 7/16" dia. (qty. 10).
Pinion diameter/splines: 1.625 / 30.
Axle shaft/splines: 1.320 / 31.
Rotor thickness (where it mounts to axle is .250").
Overall width 59.625" (the F8.8 is .950" narrower then a TJ Dana 35).
(The F-150 8.8 is drum brake and width WMS to WMS is 65.5”.)
Hole diameter for ABS sensor in top of housing: .811".
Bolt size (U-joint flange to yoke) is: 12 x 1.75 x 30 mm
Centerline of housing to C/L of pinion difference is 3.875" toward the P/S.
Pinion offset: P/S to C/L of Pinion, 27-3/4" (no rotor on axle), D/S to C/L of Pinion, 31-5/8" (no rotor on axle). (this measurement is 2.5" more offset to the P/S then a TJ Dana 35).

Specs:
Code Capacity Ratio
43 Open 3200 3.08
41 Open 3200 3.27
42 Open 4.10
46 Open 3.73
45 Open 3200 3.55
D4 Limited Slip 3200 3.73
D2 Limited Slip 4.10
L73 Limited Slip 3.73
L - Limited Slip Differential
C - Conventional Differential

Thanks Chris Overacker for the specs and measurements! see his website link below.

How many splines are the axle shafts?
drivers side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 30-1/2 inch length - 5 X 4.5 inch lug pattern.

passenger side is 31 spline for 97 & up Mountaineer, 95 & up Explorer, 27-5/8 inch length - 5 X 4.5 inch lug pattern

Can I get 35 spline shafts? Yes, with a little searching I found 28 and 33 splines too. Remeber 8.8 axles are used on many different Ford rigs. Mustangs, Rangers, F150s, Aerostar etc... different axle lengths than the Explorer so if you are looking for aftermarket products make sure you are not looking at something for a Mustang that might not fit an Explorer. For the 35 spline stuff check with Mark Williams site. i dont have a link yet but i will soon.

Do I need a slip yoke eliminator? In my opinion, yes

Can I use my drive shaft that I bought for my SYE/Dana 35 set-up? Yes

Is the 8.8 narrower than a Dana 35? Yes but not enough to make a difference when running most aftermarket wheels.1.5" shorter or so. It doesn't matter unless you try running stock rims w/12.5 or wider tires.

Are the 8.8 shafts stronger than Dana 44 shafts? Yes, also the bearings, pinion and ring gear are also much larger.
Axle shaft Strength and output torque rating by Warn and 4 Wheeler

The axle shaft strength tested by Warn Ind:
F8.8= 6,500 (lb. ft.)
D44= 4,600-5,000 (lb. ft.)
D35C= 4,000-4,300 (lb. ft.)
-------------------------------
COT: Continuous output torque rating
MOT: Maximum output torque rating

(Numbers from January edition of Fourwheeler, page 60.)
Dana 35 rear axle COT: 870 MOT: 3480
Dana 44 rear axle COT: 1100 MOT: 4460
Ford 8.8 28spline COT: 1250 MOT: 4600
Ford 8.8 31spline COT: 1360 MOT: 5100
Dana60 semifloat COT: 1500 MOT: 5500]
(thanks joe and Chile99.)

Will I need that brake proportioning valve from a Rubicon? Maybe

Does the 8.8 offer more ground clearance over the Dana 35 and 44? Not under the differential but the bigger axle tubes lift the rig about 5/8 ".

Is there welding involved? Yes, but the new brackets you put on are much stronger than stock Dana’s. Not a good idea to re use your old Dana 35 brackets

Where do I get brackets?
4x4 Group Buy has Rubicon Express for $225+shipping.
Bob Supplee has Tera for $220 shipped.
DC4WD has Tera for $217 shipped. thanks jamie 9/21/05

Jeepers and Creepers
TeraFlex TMI-ABK-TR $250.99
M.O.R.E. Dana 35 brackets (sku:MORE98700)
Rubicon Express RE9969 TJ Axle Bracket Kit Rear
Mad4wd.com (sku:Mad-BKTK-TJ1)

Link to axle bracket placement on Stu Olson's site
The list above should get you headed in the right direction as far as brackets go. Look around and compare prices as the brackets can be found for $200.00 or less shipped sometimes. Keep this in mind when shopping for any item for your build-up,if you do, you will save a bundle.

Can I reuse my Dana 35 brackets? Yes, but it is not recomended. The stock Dana 35 brackets are sort of flimsy compared to the beefy aftermarket versions. Some of the brackets available are in fact for Dana 35 axles to replace the weak ones that come factory. Reusing the D-35 brackets is time consuming even if you have the right tools, not a good idea IMO

Should I weld the axle tubes to the cast housing? I would if it had been salvaged from a wrecked rig. If it is new on a crate (in my opinion) don’t bother.
(picture of joe dillard's axle tube welds below.)

Will my stock sway bar work? Yes, with a minor modification to a passenger side pinion gusset.

Do all 8.8s come with a limited slip? No, read the tag on the housing or remove the cover. 3L73 = 3.73 gears witha "L"imited slip

Where is the gear break for lockers? There is no break. Same locker for 3.73 to 6.14

Do I need a notched cross pin? Yes for 4.56-6.14 to clear ring gear, or notch a gear tooth.

More cross pin info from NovaTJ:
The 3/4 inch cross pin only fits those rears with the 28 spline count period!
Therefore, the 7/8 inch crosspin is what we are concerned with and it fits Explorer, Mountaineer, F150, and Expedition's with the 8.8 ring gear and 31 spline axles. It also come in those special Mustangs that have the 31 spline axles i.e. Cobra, Steeda, and Rousch.

The axles for Jeep conversion we are keen on are the 96 through 2001 Ford Explorer and Mercury Mountaineer with disc brakes and all that fall into this category with or without limited slip have the 7/8 inch cross pin.

What year ford explorers do I look for as a donor for 31 spline and disc brakes? 1995 to 2001.

What is so great about 8.8? Parts are everywhere, as in axle shafts, covers, brake parts etc..

What's not so great about the 8.8? Weak stock carrier, replace with a carrier type locker like ARB or Detroit (not a lunch box type) this will cure the problem.

Spun axle tubes: Simply weld the tubes into the diff housing before they spin. You are welding to cast steel so now would be the time to ask for a professional's opinion. I have heard of guys tossing the works in a oven before welding, some just go at it cold. Both say their way is right.

Thin stock diff cover: Get some armor.

(my axle was new surplus and had not been in a collision, i know exactly where it has been from mile one and it is not welded. I dont believe my wheeling style will cause me problems, however i do keep a close eye on the plug welds.)

What kind of locker can I get? Thanks Joe
$690.48 ARB SELECTABLE AIR LOCKER
$342.69 AUBURN GEAR - HIGH PERFORMANCE LIMITED-SLIP DIFFERENTIAL
$424.22 AUBURN GEAR - PRO SERIES LIMITED-SLIP DIFFERENTIAL
$535.72 DETROIT LOCKER
$229.59 E-Z LOCKER - FITS IN FACTORY NON-POSI CASE
$641.96 EATON - ELOCKER SELECTABLE LOCKING DIFFERENTIAL
$388.20 EATON - POSI LIMITED-SLIP DIFFERENTIAL
$209.04 FULL SPOOL - 31 SPLINE - STEEL
$118.46 MINI SPOOL - 31 SPLINE - C-CLIP COMPATIBLE - STEEL
$348.40 ORIGINAL STYLE POSI - COMPLETE
$261.52 POWERTRAX - LOCK-RIGHT LOCKER - FITS IN FACTORY NON-POSI CASE
$381.94 TRUTRAC LIMITED-SLIP
(prices will vary)

What is the bolt pattern? 5 on 4.5” just like stock TJ/YJ wheels.

Will my Jeep lug nuts fit the 8.8? In most cases, yes.

What do I do with the speed sensor? leave it in place.

Where to buy?
Car-part.com
www.ok4wd.com
wallysheata, Ariel Performance
www.alljeep.com
http://www.rockequipment.com
to name a few.

How much do they cost? Free to $1500.00 but you can find them new for around $500.00 in their stock form complete disc to disc.

What do I need for a swap into a tj?
Here are some things I used:

-TeraFlex Bracket kit
-ARB
-U.S. Gears 4.56
-Master install kit (Timken)
-Crane diff cover
-Napa brake line kit P/N 380528 (x2)
-T-hose NAPA P/N 380889
-ZJ E-brake cables (drivers and passenger side)
Mopar P/N 52008904 & 52008905 NAPA P/N 95533 (right) 95322 (left). (not for YJs)
-Driveshaft adapter: Spicer 2-2-1379
-Flange bolts Ford P/N N800594-S100 (x4)
-'03 TJ Rubicon (w/disc) proportioning valve P/N 5083808AA
-3/16" hard brake line about 40" & 18"

HELPFUL SITES be sure to check these out:
Stu-Offroad
Dome & Detour
8.8 Swap
J.E. Towle / DPG Offroad
Chris Overacker / CODE 4x4
Stormtrooper
4x4 Wire Links
The Ranger Station Tech Library
The Ranger Station Tech Library 2

YJ & XJ STUFF:

From M.O.R.E.
-XJ Installation Kit P/N 98600 84-2001 XJ
-XJ E-Brake Cable Kit P/N EB3 Disc Brake F8.8 Only
-Special Yoke P/N 221379 F8.8 to 1310 U-Joint

From Dealership:
-Mopar spring perches
-Tabs for shock mounts
-ZJ ebrake cables from the dealer (for XJ install)
-Flange from spicer dealer $30 (have seen this go from $20-$50)

A BIG THANKS TO ALL THOSE WHO PARTICIPATED IN THIS THREAD!!! (whether they knew it or not)

BENT SHAFT????
Joe Dillard's 8.8 Shaft Replacement Thread
Joe Dillard's Super 88 write-up!

Here is a 8.8 DISC BRAKE HOW-TO from Autozone's website. clicky-clicky...

8.8 PART NUMBERS:
Rear Caliper Bolts p/n N606046-S60 List $4.10 each (9/06)
Flange bolts P/N N800594-S100 $1.29 (x4) (5/05)
If you have some Ford part numbers you want to ad just pm me.

[xj97jks]

I looked into spooling my 8.8 and I ran into tons of problems with c-clip eliminators and being able to find them. Would a mini spool be an easier way to go considering that its c-clip compatible? What is the difference between the spool, and mini spool?

[xjfever]

What size tires do you plan to run? Also is your rig gonna be a "beat the crap out of it till it breaks" offroad only rig, or a daily driver that gets offroad once in a while? Because if you're running 33's or smaller, and not beating it to death, the 97-up 29 splined 8.25 will bolt right in and get the job done. And I'm not saying you can't run larger than 33's on the 8.25, just that with 33's or less I wouldn't worry at all about it.

[bills79jeep]

There are 2 good write-ups in the stickies about 8.8 swaps under axel's as well. Pictures and whatnot as well.

[TreddyoXJ]

Originally Posted by fphipps

so i have seen people put ford 8.8 rear axles on thier xjs and i was wondering how hard it is to do that?im looking for a better axle to replace my Dana 35.....would it be easier to just a C8.25?

It would be much, much easier to just swap in a 29 spline C8.25. The perches and shock mounts are already set up and it will bolt right in. I bought a Ford 8.8 at one point and ended up ditching it because the project was more than I was able to undertake/fabricate/afford.

With the Ford 8.8, you will need to remove the stock perches, relocate them; do the same thing with the shock mounts; probably have to regear it or your front axle as the gearing in most 8.8's is different than stock gearing in XJ's; buy a new driveshaft as the stock one will not bolt up to the new yoke or be the right length for the housing.

IMHO, if you're looking to simply upgrade your rear end, find yourself a 29 spline C8.25" or find a Dana 44 out of an old XJ. If you're going for the extreme, don't use a Ford 8.8. If you really are going to build something bombproof, go the route of a Dana 60, Dana 70, or 14 bolt. By the time you drop all the money into a Ford 8.8, you could've built a much stronger axle for the same amount of money. Good luck!

[jeepjack1995]

book marked yo

[jonzer12]

Originally Posted by TreddyoXJ

It would be much, much easier to just swap in a 29 spline C8.25. The perches and shock mounts are already set up and it will bolt right in. I bought a Ford 8.8 at one point and ended up ditching it because the project was more than I was able to undertake/fabricate/afford.

With the Ford 8.8, you will need to remove the stock perches, relocate them; do the same thing with the shock mounts; probably have to regear it or your front axle as the gearing in most 8.8's is different than stock gearing in XJ's; buy a new driveshaft as the stock one will not bolt up to the new yoke or be the right length for the housing.

IMHO, if you're looking to simply upgrade your rear end, find yourself a 29 spline C8.25" or find a Dana 44 out of an old XJ. If you're going for the extreme, don't use a Ford 8.8. If you really are going to build something bombproof, go the route of a Dana 60, Dana 70, or 14 bolt. By the time you drop all the money into a Ford 8.8, you could've built a much stronger axle for the same amount of money. Good luck!

I disagree %100 percent. Ruff Stuff specialties has 8.8 XJ install kit is just over $100 bucks. All you really need is a new driveshaft/yoke/flange, not terribly espensive and required REGARDLESS of what ever axle you swap it.
All you really need to buy is E-brake cables. The best part of it is that you get disk brakes! We did my buddies before I had my welder and he just bolted it up and drove it extremely slowly (about 1/2 miles) to a shop to have the spring perches and shock mounts welded. All said and done he did the swap for under $500. With the super 8.8 kit as an upgrade path the 8.8 is almost perfect as a first axle swap. The disks setup alone pays for the swap.
If you don't need to rebuild the 8.8 it is cheap as hell, especially since they came in 3.55, 3.73 and 4.10