Daily Driver 5.9 build thread - bumpers, tube rockers, etc.. - Page 3 - JeepForum.com
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Unread 12-29-2011, 12:06 PM   #31
Timo_90xj
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Well guys, you can officially call me crazy Polishing a turdy - or in this case the D44a - is one of those things one really shouldn't do

Anyways, pinion and carrier bearings are toast and pinion seal is leaking slightly on my D44a. So it's time for a re-build. Due to local laws I can't delete the ABS from my ZJ. Hence I can't swap in a Ford 8.8 - especially so 'cause they cost a lot here. So the easiest option is to upgrade the D44a.

I happened to come across a free D44a axle housing that had it's guts removed. Axle is dead-straight, bearings caps are there, and none of the bearings have spun inside the housing. So it's a good starting point.

Things I'm doing:

1. Fab a truss to reduce housing/ axle tube flex
2. Incorporate some kind of system to protect the underside of the aluminum housing. It gets rock rash pretty damn easily
3. Add an aftermarket diff. cover to reduce housing flex
4. Fab new UCA + panhard mounts, beef up/ modify the LCA + shock mounts
5. Install 4.56 gears; if I can find a cheap (free) open carrier I'll add a lunchbox locker. If not, I'll get the LSD rebuild kit.

After that, it should be strong enough to handle what I use it for. A lot of work? Maybe, but I don't care. At least I get some time spent in the garage instead of working outside on the rain building my house


I have a spare HP D30 in the garage, so I'll do something similar to it: fab a basic truss, add a heavy duty diff. cover, 4.56 gears + Eaton e- locker. I've also had WJ- knuckles and brake parts sitting in my garage for about two years, so they'll be swapped in as well.

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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 12-29-2011, 06:33 PM   #32
MilanJeep
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Damn! DDing a 5.9 with European gas prices...you must be rich lol
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Unread 12-30-2011, 01:54 AM   #33
Timo_90xj
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Quote:
Originally Posted by MilanJeep View Post
Damn! DDing a 5.9 with European gas prices...you must be rich lol
Yeap.. at the moment it's around 7.50-7,70$/ gallon (1.50-1.55€/ litre) ..and people wonder why I do some of my commuting by bus and metro
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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 12-30-2011, 06:12 AM   #34
melk
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I love the recessed winch and front skid.

Custom fab ftw!
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Unread 12-30-2011, 09:44 AM   #35
jeep0312
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Keeping an eye on the D44a build. I'm keeping mine and need to build it up.
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Unread 12-30-2011, 06:17 PM   #36
mtnmarc
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Quote:
Originally Posted by Timo_90xj View Post
i realllllllly like how much the winch doesnt stick out. i hope to be that close when i build my bumper.
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99 WJ hp44, 3 link, Eaton e locker, 14" foa coilovers in the front. 14 bolt, 4 link, grizzly locker, 12" foa coilovers in the rear. 5.38s and 37s
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Unread 12-30-2011, 07:14 PM   #37
98zjkidd
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Did u really cut up that niner grill??
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Unread 12-30-2011, 11:26 PM   #38
Timo_90xj
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Quote:
Originally Posted by 98zjkidd View Post
Did u really cut up that niner grill??
Well, how could I stick a standard grill in there, wouldn't look like a niner then

My reasoning was, since I recessed the winch so deep in there and did all the mods in the front I'm not needing the grill as it came from factory. Yeah, hurt a bit doing so, but I tried doing this so the niner looks as good as possible
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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 01-15-2012, 10:34 AM   #39
Timo_90xj
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Rear truss starting to take shape..




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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 01-15-2012, 01:41 PM   #40
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...I love this zj

really interested in what you're doing with your D44a
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Unread 01-16-2012, 10:49 PM   #41
big_rudy101
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That looks awesome man. Nice work! Superrrrr jealous!
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Unread 01-18-2012, 07:45 PM   #42
Dyn0mitemat
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Love the tube work.

Just an FYI but its fairly easy to get abs working with an 8.8 (mallcrawlin has a writeup), but if they're too hard to find there then thats cool. Nice to see someone give some love to the aluminum (is it alum-inum, or alu-minium? )
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Unread 01-22-2012, 01:33 AM   #43
Timo_90xj
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We went snow wheeling yeasterday, it was a lot of fun. Then again, wheeling in winter makes things that little bit harder and way more different, and all sorts of things can happen on the slippery trails.

Whoops








Which results in this The damn 31" BFG AT (didn't have my own spare tire with me ) made things a lot more difficult, without a front locker I really wasn't moving anywhere after this. Difference in grip was huge between a 32" BFG MT and the AT..

It was left rear that punctured, but I had to swap the smaller AT to the front and my left front to rear, so when I got out of the trail I removed the front DS and drive back home in RWD.. In this case, I wish I had a 242 or 231.. This is the biggest downside of an AWD transfer case.

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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 01-22-2012, 10:42 AM   #44
squazz
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awesome skillz
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Unread 01-22-2012, 11:32 AM   #45
PolkaPower
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Or just carry your spare

Do you listen to any of that Black Metal like Sentenced or Purtenance?
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