[GreenJip]

I got a little bit more done to the 8.8. I cleaned the paint away from the tubes and housing to weld the tubes and brake hose mounts. Since the housing is cast steel, I went with some suggestions on this thread and my buddy confirmed with a welding shop that it would be ok to mig the tubes to the housing. So I hauled it over to mjstranz house and he miged it up for me.



Also, we welded some nuts and tabs to the tubes so I can secure the brake hoses. Its pretty ugly, but it holds and I am ok with that until I can think of something better. Until then, I am forward thinking.



We also knocked the old bearings out with a long piece of DOM tubing and huge sledge. I think I heard them quiver when we wacked em. Since I had the parts with me we put the new bearings and tubes in.



Its too cold to paint, so I am going to wait until it warms up to finish that. All thats left is to order an SYE and get my salvaged CV joint shortened and I am ready to put this in! I will post updates when the SYE comes in. Its looking like February.

[GreenJip]

Well, today I ordered in the last of my parts. I have updated everything I have for this build on the second post. Obviously this is not the cheapest route considering I havn't got a locker or changed the gears, but alot of the things I ordered will be needed for any axle swap and lift kit. This has also been a really fun build for me.

Hopefully if everything comes in by Friday, I can start the final instal. Once everything is installed, I can get the drive shaft measurement. Alot of people around here have recomended Clinards Driveshaft in Nashville. I will post the process if it happens this weekend.

[mjstranz]

Clinards does good work, Nicks here in cookeville is good shaft shop too, and hes a bit cheaper.

[GreenJip]

I got alot done toward getting the 8.8 finished this weekend. My buddy came over Saturday morning and helped me put the SYE in. It took longer than expected because we had to move the exhaust out of the way to disassemble the case. I have an after market muffler and it is just too big for clearance. Heres a pic of the SYE and muffler clearance. I am definatly going to have to reroute that at a local shop.





Later that afternoon, I pulled the dana 35 out for the last time!



Putting it in was difficult by myself, but after some grunting I got all the arms loosly bolted up and raised the axle to set the pinion. I have it set roughly at 16*.

I also put all the brake components on and the shafts. I was worried about the shocks clearing the brake lines, so I lowered the axle to check for clearance.



Here is a pic for the stainless line I ran from the axle to the frame lines. I dont have any mounts, so I spliced some rubber hose to protect the hard line and zip tied it in place.



I ordered an adapter bracket for the parking brake so I could use my stock cables. Here is how that set up looks like. I am happy with the fit.



Here is the last pic of the brake assembly where the hoses are mounted to the axle.



I put the springs in and secured all the suspension and then put the full weight of the jeep on the axle. This was a good oportunity to measure the drive shaft length. I got 20" for my set up. It will most likely be different depending on what your set up is (lift, SYE, MML and so on). My only concern about the suspension right now is the springs. They arch a bit and I don't know if this is any concern. Heres a pic and any feed back on this would be appreciated.



Well, all I have left is to get my drive shaft shortened, confirm the pinion angle, bleed the brakes and get the muffler rerouted. For now, heres how the Jip sits!

[dae03TJ]

looks really clean great work!

[Chris_]

Where did you get your E-brake adapter?

[GreenJip]

Originally Posted by Chris_

Where did you get your E-brake adapter?

www.crawlertech4x4.com You will have to get the contact email off their web site, the product is not listed there. The guys name is Josh and he is real good to work with. $40 beats new ZJ cables.

[Chris_]

$40? That's almost the price of the ZJ cables. I'm just going to use the U-bolts for now. I've got to get them hooked up this weekend.

[mdm]

Originally Posted by GreenJip

…My only concern about the suspension right now is the springs. They arch a bit and I don't know if this is any concern…

Your springs are arched like that because you did the following:

Originally Posted by GreenJip

…
We set the pinion at 10*. This was the stock pinion angle. … I will also be running a JB Super Short SYE, CV rear shaft adjustable upper control arms and an adjustable rear track bar. So, I will have plenty of room for changing the pinion if I need it…

You already knew you would be installing an SYE, CV drive shaft, and needing to adjust the pinion. The pinion should have been set up at a more realistic angle of 15-17 degrees instead of the stock angle.

Originally Posted by GreenJip

…During the first test fit, we tacked the coil buckets in place. We just set them up there and made sure they were centered and at the same angle. We pulled the axle out and welded the coil buckets ...

You set up the coil buckets at the same wrong angle you used for the pinion.

Originally Posted by GreenJip

… I got all the arms loosly bolted up and raised the axle to set the pinion. I have it set roughly at 16*…

Now that you have adjusted the pinion to a more proper angle you have the problem with the coil buckets and the arching springs. The other thing setting the brackets up using the “stock” pinion angle is that it rotates the track bar bracket back towards the fuel tank when you adjust the pinion to the real angle. This may create a bind in the track bar bushing and not allow as much flex as you would have gotten if the brackets were set up properly.

[GreenJip]

Originally Posted by mdm

Your springs are arched like that because you did the following:


You already knew you would be installing an SYE, CV drive shaft, and needing to adjust the pinion. The pinion should have been set up at a more realistic angle of 15-17 degrees instead of the stock angle.


You set up the coil buckets at the same wrong angle you used for the pinion.


Now that you have adjusted the pinion to a more proper angle you have the problem with the coil buckets and the arching springs. The other thing setting the brackets up using the “stock” pinion angle is that it rotates the track bar bracket back towards the fuel tank when you adjust the pinion to the real angle. This may create a bind in the track bar bushing and not allow as much flex as you would have gotten if the brackets were set up properly.

I came to that conclusion too after I put it in this weekend (lesson learned). My concern is driving it like that. Do you think there is a minor fix to the track bar mount? Also, is that arched spring going to cause me any problems driving?

[GreenJip]

Originally Posted by Chris_

$40? That's almost the price of the ZJ cables. I'm just going to use the U-bolts for now. I've got to get them hooked up this weekend.

How much are they? I thought it was significant. I could have been wrong.

[Chris_]

That shouldn't be any more of a problem than people who add an SYE to their stock D44s that are set with a factory pinion angle of around 10*. I put my brackets on at a 15~16 pinion angle, and I'm still using the factory track bar.

Originally Posted by GreenJip

How much are they? I thought it was significant. I could have been wrong.

About $25 a side. That's what a friend of mine at a dealership quoted me.

[1CleanTJ]

i know this isnt what you want to hear, but the only way to correct that is to drop the axle, grind the welds off and reposition the axle brackets. How you have it right now your going to have binding issues and less flex, the gas tank to trackbar clearance may be pretty close too

[GreenJip]

Originally Posted by Chris_

That shouldn't be any more of a problem than people who add an SYE to their stock D44s that are set with a factory pinion angle of around 10*. I put my brackets on at a 15~16 pinion angle, and I'm still using the factory track bar.



About $25 a side. That's what a friend of mine at a dealership quoted me.

Well, $10 is $10. I broke even with the shipping though.

[GreenJip]

Originally Posted by 1claentj

i know this isnt what you want to hear, but the only way to correct that is to drop the axle, grind the welds off and reposition the axle brackets. How you have it right now your going to have binding issues and less flex, the gas tank to trackbar clearance may be pretty close too

I got my drive shaft done today. So, TimBrown came over and helped me set the pinion at the right hieght. I miss measured the pinion earlier. It was set at 17* and I was able to pull it down to 14.50. I am one degree lower than the drive shaft so that I can compensate axle wrap on take off.

After setting it up the springs straightened out a "little" and the track bar has no binding issues. I also have plenty of clearance from the gas tank.

I really appreciate everyone's input so far. Like Chris_ said. Its no different than a stock dana 44 being set up with an SYE, so that calmed my nerves a bit. Over all, I am real happy with the way its turning out. I need to adjust the track bar in a little to center the axle better.