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Go Back JeepForum.com > General Jeep Forums > Jeep Builds > 91 YJ D60 swap - Build Thread

BLACK FRIDAY SPECIALS!! You asked, we deliver!Rough Country Lift Kits and Parts!XJ Rail Sale!

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Unread 11-30-2009, 03:53 PM   #16
AuroraJeep
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1999 TJ Wrangler 
 
Join Date: May 2008
Location: Hampton, VA
Posts: 342
Alright, so I am list person and maybe this list will help someone else out.

My Axle Swap To Do List
-REAR AXLE-
Pull rear axle*
SYE kit*
Take off old springs*
Clean and paint rear frame*
Install new springs*
Weld on spring perches*
Weld on shock mounts*
Weld brake line brackets*
Paint axle*
Weld on shock towers*
Install axle*
Rebuild drive shaft*
Shorten drive shaft*
Install shocks*
Install drive shaft
Run hard brake lines
Install soft brake lines
Install breather hose
Flare and repair body hard line

-FRONT AXLE-
Pull front axle*
Remove springs*
Paint front of frame*
Install new springs*
Install shock stud conversion*
Paint axle*
Install axle*
Install shocks*
Rebuild drive shaft*
Measure for steering
Ream pitman arm
Install steering
Install calipers and pads
Install breather hose
Measure for soft brake lines
Install soft brake lines
Bleed whole brake system
Tighten all bolts
Full t case and axles with fluid

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Unread 12-07-2009, 04:18 PM   #17
AuroraJeep
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Sorry I have been not the greatest and posting my progress. The front D60 is in and the drive shafts done. I will post some pictures soon. I did score some tires. 39.5x13.5x17 Iroks.
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Unread 12-18-2009, 10:21 PM   #18
AuroraJeep
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Ready for some updates and pics?

Here is the front axle painted and installed under the Jeep... also installed the stud shock conversion from JKS and the lock nuts were a pain!



Got my tires as seen above and I love em. I have to balance them, I am leaning towards air soft pellets to balance them out. They are on dodge ram power wagon wheels so it will bring the stance in a little tighter.


Got my WFO steering, both tie rod and drag link and it's awesome! Trevor, owner, from WFO is the best, I ordered it straight from him and he asked all about my build to make sure I got the best product for my build. Its directly tapped DOM tube with Chevy tie rod ends.


I also got some more of my brake parts. I bought 30" lines all the way around with AN adapters to fit the hard lines. I talked to some other people and they all have had great results with Earl's braided lines. Jegs is a little slow on the delivery, 3 and half weeks later I am still waiting on 2 out of the 3 lines.


While I was at Auto Zone, I picked up this little t-case shifter. I got this thing with skulls, I have 4 of them tattooed in my sleeves, wife loves em.
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Unread 12-23-2009, 02:52 PM   #19
H102
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Great build. Did you have the axles narrowed up at all or are they full width still?
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Unread 12-23-2009, 04:02 PM   #20
black954
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great build
I think it's funny that I noticed the IROC's in the picture from my local craigslist add and then I noticed you're in Aurora LOL! You got a great deal on them and the F250. Let me know if you need a hand with anything as i'm only 10 minutes away and wouldn't mind checking out the jeep anyways.
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Unread 12-23-2009, 04:07 PM   #21
Mark4883
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Man those are some beefy axles, lookin good.
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Unread 12-23-2009, 04:39 PM   #22
corndogduff
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YJ on tons
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Unread 12-23-2009, 08:04 PM   #23
Ingle47
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Nice Axles, So how many hours do you have in the swap so far, keep us up dated with pics
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Unread 12-24-2009, 05:45 PM   #24
badabing68
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nice build...I just picked the same knob for mine also.
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Unread 12-25-2009, 08:50 PM   #25
1992 renagade
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Any pictures of it sitting on the new wheels and tires? Keep up the good work.
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Unread 12-26-2009, 08:29 AM   #26
AuroraJeep
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Quote:
Originally Posted by H102 View Post
Great build. Did you have the axles narrowed up at all or are they full width still?
Yep, full width axles.

Quote:
I think it's funny that I noticed the IROC's in the picture from my local craigslist add and then I noticed you're in Aurora LOL! You got a great deal on them and the F250. Let me know if you need a hand with anything as i'm only 10 minutes away and wouldn't mind checking out the jeep anyways.
Yeah man you can swing on by sometime, I usally work on it on the weekends with work and all.

As far as the hours put in, I really could say maybe a week to week and half total. I have been working on it like 2-4 hours at a time. No pics of the tires on yet. This weekend I plan on throwing the steering and brake lines, then the tires go on. And there will be pics posted.
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Unread 01-03-2010, 06:47 PM   #27
AuroraJeep
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I got the back brakes all done. I have 10" braided lines to the calipers, and new hard lines to the new distribution block with 3/16" hard lines all around. I had to re-flare the body hard line because it snapped off. First time I double flared and I think it turned out well, but we will see once the fluid is in. I have a 30" braided lines from the block to body hard line. It's a bit over kill as far as length but it will be good once I stretch the rear end with a Cherokee leaf springs or linked in the future.



I also put the steering in. I had a time with the taking off the pitman arm. I broke one puller and started to break a second one when I just gave in and reamed the arm attached. I painted the links flat black to match the rest of the suspension. The steering is beefy!
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Unread 01-03-2010, 07:08 PM   #28
TYphoonXJ
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Siiick! Cant wait to see this puppy with tires!
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Unread 01-04-2010, 09:21 AM   #29
black954
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Looking real good
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Unread 01-11-2010, 09:14 AM   #30
AuroraJeep
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Little update with no pics:
Finished running the brakes, just have to bleed the system. I am not really looking forward to that. The system is all but dry, should be lots of fun

Bought some airsoft pellets to balance the tires and divided them up for $20 total, 10oz per tire. When it warms up a little I will install them.
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