Axle swap guide - 1/2 ton - Page 6 - JeepForum.com

Reply
 
LinkBack Thread Tools
post #76 of 97 Old 06-30-2014, 08:28 PM
dlundblad
Registered User
2003 WJ 
 
Join Date: Jun 2009
Posts: 585
Dang Tom! I had no idea you were putting this beast together. It is looking exceptionally well. Great job on all the welds and detailed pics.


03 WJ Laredo 4.Sl0w
16" JK alloy take-offs
2" BB, Goodyear AT's
dlundblad is offline  
Sponsored Links
Advertisement
 
post #77 of 97 Old 07-15-2014, 06:27 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
Quote:
Originally Posted by fast540 View Post
Mr skain, nice to see your rig together. Bet you won't be breaking axles anytime soon
Thank you, sir. Doubt it!

Quote:
Originally Posted by dlundblad View Post
Dang Tom! I had no idea you were putting this beast together. It is looking exceptionally well. Great job on all the welds and detailed pics.
Thank you as well, sir.

Quote:
Originally Posted by thejeep88 View Post
You gonna have this beast at the all breeds jeep show in a few weeks?
Doesn't look like the jeep will be there, but I plan to. Look for EndlessMtnFab!

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #78 of 97 Old 07-15-2014, 06:33 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
9" drain

Added a drain to the 9". Props to StrokedWJ for the suggestion and the pic earlier in the thread. Here's what we came up with for max function and low-profile protection -- you can see it is recessed, reinforced (just a tad ), and a magnet was jb welded to the to inside plug to catch any metal. Notice the rear truss burn marks on pic #4?

Name:  drain 1.JPG
Views: 296
Size:  148.1 KB

Name:  drain 2.JPG
Views: 297
Size:  154.2 KB

Name:  drain 3.JPG
Views: 297
Size:  138.5 KB

Name:  9paint.3rd member,drain.jpg
Views: 301
Size:  214.8 KB

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #79 of 97 Old 07-16-2014, 11:13 AM
StrokedWJ
Web Wheeler
 
StrokedWJ's Avatar
2000 WJ 
 
Join Date: Oct 2007
Location: Asheville
Posts: 3,076
^ Nice work! That came out really nice!

2000 WJ 4.5L - Stroked, Locked, & Long-Armed
Looking for 6" WJ springs!
StrokedWJ is offline  
post #80 of 97 Old 07-21-2014, 06:05 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
Front & rear swaybar

Front swaybar is retained. Creativity was needed for the front swaybar links in order to achieve optimal angle (i.e. parallel with the lower control arm) while avoiding any interference of the front steering or suspension. Here is the driver's side design. Passenger is similar, and was much easier since no steering links to contend with. WJ style JKS disco's are used (open loops top/bottom). The pics are a bit deceiving -- there is plenty of clearance between the link arm mount and the trackbar.

front-swaybar-link.jpg

front-swaybar-link-2.jpg



Rear swaybar is mounted to the truss. If the gas tank was raised, it could be mounted much higher up, but as it currently sits, there is no clearance issues with the stock tank skid. Rear swaybar links are JKS disco's (not pictured) -- not for disconnect function, but moreso for flex. I like the stock rear swaybar connected.

rear-sb-bushing-view.jpg

Name:  rear sb.JPG
Views: 250
Size:  179.2 KB

rear-sb-side-angle-2.jpg


In this pic, you can also see the rear shock mount. The goal was to position the shock for optimal dampening (i.e. as close to perpendicular to the ground as we could get, within reason given design limitations).

Name:  rear shock swaybar combo.jpg
Views: 254
Size:  265.5 KB

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #81 of 97 Old 07-21-2014, 06:13 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
Quote:
Originally Posted by StrokedWJ View Post
^ Nice work! That came out really nice!
Thanks.

Provided some more content re: ABS, speedometer and brakes (prop valve) early in thread at post #5.

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #82 of 97 Old 08-26-2014, 06:53 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
POR, primer & paint on the 9"

Light dusting etch primer after bare metal was POR'd:

Name:  9 primer front view.jpg
Views: 1226
Size:  77.4 KB

Name:  9 primer rear view.jpg
Views: 250
Size:  72.5 KB

1st coat topcoat:

Name:  9 black topcoat rear view.jpg
Views: 248
Size:  105.4 KB

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #83 of 97 Old 09-02-2014, 07:13 AM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
PM's replied to. If you have a specific question, please just post it and I'll do my best to answer.

Also, I added some additional info regarding the speedometer in post #5. BTW, anyone have a 39 tooth speedo gear laying around?

Cheers.

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #84 of 97 Old 09-02-2014, 10:00 AM
mtnmarc
Registered User
1999 WJ 
 
Join Date: May 2009
Location: Grass Valley
Posts: 1,541
Glad to see you figured out the speedo wiring man!

It was a pain when I did it cuz not a lot of true info was out on the interweb. A few people had ideas, but nothing really to follow. And that was a good thing to say that Chrysler has different colors for wires, because I ran into that issue first hand. Haha. Where are the full widths and coilovers

And with the speedo gear, mine with 5.38s and 37s is dead on with a 41 tooth I believe.

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
mtnmarc is offline  
post #85 of 97 Old 09-23-2014, 05:35 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
231 speedo

As Mtnmarc wrote above, the speedo wiring was a bit of a struggle. I revised the thread a bit for that section (post #5), hopefully for others to avoid our headaches. Here is the 231 with the speedo port, which was previously sealed off:

231-open-port.jpg


And here is the finished product with the speedo gear in place and wiring run back along the rail to the driver rear speed signal wiring:

Name:  231 wiring.jpg
Views: 172
Size:  240.5 KB

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #86 of 97 Old 09-23-2014, 05:41 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
D44 updates

Here is the D44 w/primer and ready for paint:

Name:  d44 primer.JPG
Views: 174
Size:  190.1 KB

D44 back under the truck. Picture of the driver spindle, hub, lockout assembly. Note: when using manual lockouts such as Warn, the drive slug springs are not used (shown in picture for illustrative purposes only).

Name:  driver spindle.JPG
Views: 172
Size:  191.6 KB

Name:  driver spindle 2.JPG
Views: 169
Size:  174.6 KB

Name:  hub 1.JPG
Views: 173
Size:  167.5 KB

Name:  hub 2.JPG
Views: 173
Size:  130.7 KB

Name:  warn lockout complete.JPG
Views: 172
Size:  148.4 KB

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #87 of 97 Old 09-23-2014, 05:44 PM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
9" assembly

9" under the truck. Pic of the rear drums. Salvage what you can from the donor axle, but drum rebuild kits are cheap, so spend a bit for peace of mind and ease of install.

Name:  rear drum complete (1).JPG
Views: 183
Size:  143.9 KB

More pics to follow...

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
post #88 of 97 Old 09-23-2014, 07:05 PM
gtg413i
Registered User
2003 WJ 
 
Join Date: Jun 2011
Location: Bay Area
Posts: 1,427
Very nice. Can't wait to see this baby showing up some wranglers.
gtg413i is offline  
post #89 of 97 Old 09-23-2014, 07:22 PM
wvracer821
Web Wheeler
 
wvracer821's Avatar
2000 WJ 
 
Join Date: May 2010
Location: Morgantown
Posts: 1,096
really nice job on the swap, i cant wait to see this thing on the trail. ive been taking notes for when swap the 60 and 10.25 into my turd

DD: 2014 RAM 3500 Megacab Larmie 6.7L Cummins
Junk: 2000 WJ, 4.0L
Build Thread: http://www.jeepforum.com/forum/f197/...build-1436556/
http://www.pirate4x4.com/tech/
wvracer821 is offline  
post #90 of 97 Old 09-24-2014, 05:56 AM Thread Starter
skain8
Registered User
 
skain8's Avatar
2002 WJ 
 
Join Date: Oct 2004
Posts: 3,835
Quote:
Originally Posted by gtg413i View Post
Very nice. Can't wait to see this baby showing up some wranglers.
Quote:
Originally Posted by wvracer821 View Post
really nice job on the swap, i cant wait to see this thing on the trail. ive been taking notes for when swap the 60 and 10.25 into my turd
Thanks, fellas. If you have any specific questions, just ask. If I don't know, I know someone that will.

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide
231HD build info

skain8 is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome