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Unread 10-08-2013, 12:56 AM   #1
ashland82391
Out of money yet...Yup!
 
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1993 YJ Wrangler 
 
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I guess ill start with the jeep. She's a 1993 jeep wrangler with a 2.5.



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Unread 10-08-2013, 12:58 AM   #2
ashland82391
Out of money yet...Yup!
 
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1993 YJ Wrangler 
 
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A few weeks ago the turdy five started whining pretty bad, so my options were find a new d35 and pay around a 100$ or go all out on a ford 8.8! I got lucky and scored an 8.8 from a junk yard up north for 125$. Got it out of a 1996 ford explorer with disc brakes, 4.10 gears, and limited slip. I was hoping for an open but gotta take what I can get.

The explorer in the middle was the one I snagged it from.



Up in the air getting ready to get cut out by a guy that didnt know how to use a plasma cutter.



Rusty as hell!



Got her thrown in the back of my grand cherokee.



A few hours later I put it in the garage for some much needed cleaning.



4.10s



All the junk stripped off





Made sure I cut off the brake hose mounts.



cleaned





Popped the shafts out for more cleaning and painting





31 spline




The dust shields were beat up pretty bad from rust and the JY guys moving around.



I was going to buy new ones until I found out they cost over 80$ a piece! so I made them work :beerbang:



I went with this color and blue.



Let the painting begin! shafts cleaned and painted.





I was able to save one rotor and one caliper.



Cleaned and painted



rotor cleaned



primed



painted



as well as caliper mounts and dust sheilds







Now for the tear down!



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Unread 10-08-2013, 01:00 AM   #3
ashland82391
Out of money yet...Yup!
 
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comparisons





loaded up to take to a friend





ubolts, center pins, spring perches, and spring plates



Super beef spring plates from Ironman Offroad. 30$



half inch plate steel for homemade spring plates 8$. I was going to buy them but they were going to run me over 40$ so I figured why not make my own for a fraction of the price and over twice the strength.



all 10 holes drilled with regular hand drill.




old vs. new



Crappy shims removed





Tossed everything under the jeep and got the pinion angle set.



Then back into the grand cherokee to take it up north to get it welded up.



Workin my magic



Everything welded up







Axle tubes welded







Finally back home and painted



Mounted up









On all 4s!:bdr2:



Picked up a yoke adaper from the local JY off of a 91' explorer to mach the 1310 ujoint. 20$



New ujoints



final driveshaft angle, no vibes.




DONE! Total cost, including the sale of the d35, set me back 200$:nana:

thanks for reading guys!
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Unread 10-08-2013, 01:01 AM   #4
ashland82391
Out of money yet...Yup!
 
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Unread 10-08-2013, 01:42 AM   #5
Hard_oNe
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Awesome work. You inspired me to get my lazy *** off the sofa and work on mine.

How long did it take you?
What degree angle did you use?
Did you heat treat the axle before you weld the inner tube to center?
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Last edited by Hard_oNe; 10-08-2013 at 01:43 AM.. Reason: added a question.
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Unread 10-08-2013, 01:49 AM   #6
ashland82391
Out of money yet...Yup!
 
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Quote:
Originally Posted by Hard_oNe View Post
Awesome work. You inspired me to get my lazy *** off the sofa and work on mine.

How long did it take you?
What degree angle did you use?
Did you heat treat the axle before you weld the inner tube to center?
Thanks man! :-)

It took me about two weeks but that was because I ran out of money and had two wait for my next check. I could have had it done in a few days.

I really don't know what angle my ds is at, just eye balled it and called it good.lol

No, I didn't have to heat the housing. Welded just fine.
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Unread 10-08-2013, 02:06 AM   #7
Hard_oNe
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Here mine sits....need an additional funding source for parts. Mine came from a 1996 Exploder with an open 3:55 gears. I want to upgrade to 4:10 from and rear.

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Unread 10-08-2013, 06:25 AM   #8
SeanB95YJ
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Quote:
Originally Posted by Hard_oNe View Post
Did you heat treat the axle before you weld the inner tube to center?
regarding this... I'm not a metalurgist, so I don't know exactly HOW true it is, but everything I could find regarding 8.8 specs said the center is cast STEEL, and not cast iron, so if that IS true, no special prep and no special rods/wire needed for welding.

I HOPE that's true, because I didn't do anything special either when I welded my tubes - just cranked up the amperage for the thicker material. seems ot be holding fine so far.

to the OP - great writeup
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[FONT="Comic Sans MS"][COLOR="Blue"]Sean B. - Schenectady, NY - 95 YJ, 350/700r4/NP241, JB Shorty SYE, 8.8 rear, 2" BDS, 1" homebrew shackles, Daystar 1" BL, TJ flares, 35x12.50 General Grabber AT2 on 15x10 Bart D-Truckers, Polyshield polycarbonate windshield, HD over/under crossover steering
[/COLOR] [COLOR="Red"]swap/build thread: [url]http://www.jeepforum.com/forum/f22/after-almost-4-years-finally-my-own-build-swap-thread-1542284/[/url][/COLOR][/FONT]
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Unread 10-08-2013, 06:42 AM   #9
Feetwet
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Nice job!

Just one quick question.
Did you paint the brake rotor surface where the Brake Pads ride? That would not be advisable...
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Unread 10-08-2013, 06:44 AM   #10
ashland82391
Out of money yet...Yup!
 
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Quote:
Originally Posted by SeanB95YJ View Post

regarding this... I'm not a metalurgist, so I don't know exactly HOW true it is, but everything I could find regarding 8.8 specs said the center is cast STEEL, and not cast iron, so if that IS true, no special prep and no special rods/wire needed for welding.

I HOPE that's true, because I didn't do anything special either when I welded my tubes - just cranked up the amperage for the thicker material. seems ot be holding fine so far.

to the OP - great writeup
Thanks man.

I was concerned about this to but once I got welding I knew it was going to be fine. I've welded cast iron before and it was horrible. It had to be red hot before it would even start to weld.
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Unread 10-08-2013, 06:45 AM   #11
yjmike82
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Quote:
Originally Posted by ashland82391 View Post
comparisons




Super beef spring plates from Ironman Offroad. 30$
where did you get those perches?
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Unread 10-08-2013, 06:45 AM   #12
ashland82391
Out of money yet...Yup!
 
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Quote:
Originally Posted by Feetwet View Post
Nice job!

Just one quick question.
Did you paint the brake rotor surface where the Brake Pads ride? That would not be advisable...
Thanks, and yes I did. After a few times on the brakes the paint comes right off where the pad rides. No problems with braking.
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Unread 10-08-2013, 06:48 AM   #13
ashland82391
Out of money yet...Yup!
 
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Quote:
Originally Posted by yjmike82 View Post

where did you get those perches?
Ironman offroad. They are a local offroad shop. If you visit there website and get a hold of them I'm sure they can help you get a set.

ironmanoffroad.com
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Unread 10-08-2013, 06:59 AM   #14
yjmike82
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Quote:
Originally Posted by ashland82391 View Post
Ironman offroad. They are a local offroad shop. If you visit there website and get a hold of them I'm sure they can help you get a set.

ironmanoffroad.com

Thanks for the info
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Unread 10-08-2013, 07:08 AM   #15
Gage56
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Quote:
Originally Posted by ashland82391 View Post
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DONE! Total cost, including the sale of the d35, set me back 200$:nana:

thanks for reading guys!
Wow How much did you get for the d35 ? ill be lucky if i can pull 150.00 for both d30 and d35
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