My 8.8 ZJ Rear End Build Thread

redhatman · 11-05-2008, 11:47 PM

I picked up an 8.8 rear end today from an Exploder... 3:73 gears which is what I have now, some rust (has a good amount of rust, stock with fords). Now I will be working on fitting it into the rear of my 1998 ZJ in place of the Dana 35.

The axle at the pull your own parts yard was $86, but every first wednesday is half price day on parts. So $43 for an 8.8

And being I got there with about an hour to work on it, I had the guys cut it out with the torch. $50, a huge ask tractor, and a gigantic engine crane to lift the exploders rear end later, I had an 8.8. Only downside I see is drum brakes, and I noticed tonight I have two small holes in the diff cover

PICS:

I had to make sure there was metal underneath that rust!

I will need everything for this install so any links/write-ups would be appreciated. I will need the brackets and all so... yeah. Thanks

-Pat

**JeepOrvis97** · 11-06-2008, 12:05 AM

Quote:

Originally Posted by redhatman

I will need everything for this install so any links/write-ups would be appreciated. I will need the brackets and all so... yeah. Thanks

-Pat

http://www.mallcrawlin.com/forum/showthread.php?t=2880&highlight=8.8

BucYouUp68 · 11-06-2008, 12:07 AM

www.mallcrawlin.com There are some good write up's over there. Good Luck, and a screaming deal for a 8.8

FortCollinsZJ · 11-06-2008, 12:34 AM

Pat, that first link is the one I followed to prepare mine. No all I have left to get for it is the truss from claytons.

ARP wheel studs: 30$ (ish)
Spicer Dana yoke adapter: 35$ locally
Brackets and tabs: Mine are cut from a d35. I would recommend going with ballistic fab stuff though. its MAD beefy and very affordable.

Mine was 200$, but I have NEW discs on it, they are like a month old from the looks of it. It also has a LSD. You made away with a steal though.

Here is my rust bucket, turned beauty queen.

sandman · 11-06-2008, 04:00 AM

ooh! looking forward to the build. rustys has a rear axle bracket kit too, nothing as beefy as BTF though. what do you have for a welder?

redhatman · 11-06-2008, 07:30 AM

Quote:

Originally Posted by sandman

ooh! looking forward to the build. rustys has a rear axle bracket kit too, nothing as beefy as BTF though. what do you have for a welder?

I have a Clarke 130EN which is a 110 (not planning on using other than to tack) and then my buddy just bought a 220 Clarke a couple of days ago and he said I could use it. Both are Wire feed, otherwise if I feel like doing stick I know someone else that has a 220 Lincoln Stick.

**StrokedWJ** · 11-06-2008, 08:40 AM

Are you gonna try to reuse your ZJ brakes on the 8.8?

The 8.8 diff covers are tinfoil POS. Go ahead and plan on upgrading to an aftermarket cover like a MORE or Rockcrusher.

spidermonkey · 11-06-2008, 08:48 AM

Lookin good. If you have drums it is most likely only 28 spline shafts but still stout. For a diff cover I used the stock one with a $50 Rusty's diff guard. RS is the way to go if you can swing it.

Sporer65 · 11-06-2008, 11:55 AM

Quote:

Originally Posted by spidermonkey

Lookin good. If you have drums it is most likely only 28 spline shafts but still stout. For a diff cover I used the stock one with a $50 Rusty's diff guard. RS is the way to go if you can swing it.

All Explorer 8.8s have 31 splines.

Too bad on getting one with drum brakes, but I think that you should be able to switch over your brakes. But at least you got one with a limited slip.

**ArloGuthroJeep** · 11-06-2008, 12:09 PM

The stock diff cover is SUPER thin so it is a good thing that it has a hole in it...that way you are forced to upgrade to a quality version

**Jones** · 11-06-2008, 01:16 PM

Nice find redhatman. I got one about two months ago with aussie locker and 4.56 gears. Unfortunately mine came with drum brakes as well. I'm going to put 4.56 up front and do four new disc brakes.

redhatman · 11-06-2008, 01:48 PM

A couple of Questions.

1.) Will my ZJ Disc setup fit on the 8.8 with little modification? If yes, what is required?

2.) What is the big circle thing on the left side by where the input from the transfer case comes in? You can see it in the first pic.

3.) What do I need to do to my driveshaft? I have ~6" of lift now and my shaft sticks out of the t-case probably 2.5" from stock. Wouldnt the 8.8 have a bigger yoke, and therefore require a shorter driveshaft and I should be good?

4.) What about ABS and E-Brakes?

**TslAtticus** · 11-06-2008, 02:20 PM

I'm doing the same thing....eventually. I have the 8.8 w/discs and 3.55's. Is this what one would need to do the swap? http://rustysoffroad.com/mm5/merchant.mvc?Screen=PROD&Store_Code=rustys&Product _Code=RC-RAM399&Category_Code=cus

I'm going to try and cut the old ones off the d35 but in case I booger them up i want to be sure.

**Jones** · 11-06-2008, 02:39 PM

You can use that or your old mounts if you want to save money. The down side is having to cut the old ones off.

**aircruiser** · 11-06-2008, 02:40 PM

nice man, guess iron rock cleaned out the 44s and 8.8s because when i went with nick, there were a shat load of 8.8s and two 44s. oh well, atleast your ***** little 35 will be gone

abs is over-rated. so your rear-end has a limited slip now?

wow that sounds really gay

11-06-2008, 01:16 PM	#11
Jones Infowars.com Join Date: Jan 2008 Location: Arizona Posts: 7,624 Profile Gallery Classifieds My Jeeps	Nice find redhatman. I got one about two months ago with aussie locker and 4.56 gears. Unfortunately mine came with drum brakes as well. I'm going to put 4.56 up front and do four new disc brakes. __________________ What is it about Ron Paul?

11-06-2008, 02:39 PM	#14
Jones Infowars.com Join Date: Jan 2008 Location: Arizona Posts: 7,624 Profile Gallery Classifieds My Jeeps	You can use that or your old mounts if you want to save money. The down side is having to cut the old ones off. __________________ What is it about Ron Paul?