This axle is from an 89 XJ, far different from a 96. They used a 2 piece axle shaft on the pass side to save gas. It worked alright but they had the tiny older u-joints so I converted it to run my ZJs one piece shafts with the bigger U-joints. The pass side mount is a cast pice similar to the axles center section. If you look back at my pics you can see it before I cleaned it up. I just replaced the seals and made a plate to cover the hole in the back where the actuator used to be.
I would've done a write up but it's hard to keep the camera clean by myself.
It has been a great learning experience and I hope it all holds up. I have 800 miles on the rear and exept for the backlash the Detroit adds all is great. The only issue I had is that my brakes on the front stink. In low range it was hard to stop so I put on some more new goodies today. I went with stock rotors. I wanted slotted or drilled but I'm too cheap. It stops great now.
It would appear all the hard work has paid off. I did some testing to check bumpstops and the new crawl ratio. The rear tires with the 8.8, stock wheels and 1 1/4" spacers still tuck in the wheel wells. The front clears fine with the bumpstops I had, just need some minor metal trimmed up front. The crawl factor with new tires, 4.56's, and lockers at both ends is nuts! A few more miles on the front and I'm wheeling.
5.2-242 tcase-44a-30x9.50x15 MT/R-American Racing Burst Rims -[COLOR="Red"]Optima[/COLOR] -E3 plugs-[COLOR="DarkGreen"]Cu[/COLOR]st[COLOR="DarkGreen"]om[/COLOR] Pa[COLOR="DarkGreen"]in[/COLOR]t-Amsoil-Addco Front and Rear-polyurethane bushings
[B]To be installed[/B]: RE gen2 discos, military battery terminals
[B]To be rebuilt:[/B] HP30
[B]To be received:[/B]
[B]To be paid for:[/B]
[B]Next on the list:[/B] complete redo of brakes and
[B]Needed:[/B] fittings, coil of brake tubing, Russel speed bleeders
The Exploer wheels work great on a Jeep but mine had pretty good rash. At the time I had 4 sets of wheels so I sold them cheap. Then I went to the eagle alloys. I liked them but polished wheels don't mix well with rocks and iron ore. It could stain them pretty bad. I sold them with my 31's so I wouldn't have to pay to unmount them.
stock ZJ low pinion Dana 30-notice the passenger side upper control arm mount. It is a seperate piece welded to the axle tube and is open on the front side of the axle.
89 XJ high pinion vaccum disonnect Dana 30-notice how the mount is one solid cast piece all the way around. The mount extends across the axle tube. It also has a rectangular hole in the back to accept the disconnect actuator. Most pre 91 XJs with a 231 case had these. As well as YJs. The 242 case equiped ones had no disconnect. The idea was to save gas because by separating the two pieces of the axle the front axle assemble will not spin in 2wd. Less rotating mass. They used it on Ram trucks in the late 90"s too.