My Ford Eight.Eight Swap // Follow Along

C2U5H · 02-28-2009, 04:28 PM

It seems like a lot of people are doing the Ford 8.8 rear axle swap for their TJs nowadays, and I ran across a great deal on one from a guy in my local wheeling club (Maryland Creepers). I have the D30/D35 axle combo, and with my plans of going to 35" tires soon--as well as a Dodge 5.9L Magnum V8 swap further in the future--I thought it would be a good idea to do it. So, after researching on the swap for the past couple of weeks, I met with him and took it off his hands.

The axle is a 8.8 rear axle off of a 1998+ V8 Ford Explorer (he wasn't sure which year) ... 3.73 gears, disk brakes with internal drum parking brakes, all the hard, soft, and emergency brake lines ... it basically came right off the truck. When I talked to him on the phone he said he didn't know if it had a limited slip differential, which some Explorers came with from the factory ... we'd find out when I saw it. He was selling it because he decided to go with 40"+ tires so he was going with D60's ... his loss, my gain.

Went and met, and checked the rotation of the axles by turning the flange and by turning each brake disk ... SUCCESS!! Both disks turned the same way, it had a LSD differential!! So I gave him $300 and we parted ways.

Pulled the heavy guy into the garage, put it on jack stands, and went to work! Pulled the diff cover (ten 1/2" bolts) and the sway bar (four 1/2" bolts).

And for those of who are not doing a swap like these because you've never done one before, neither have I!! This is my first time, and with the help of the internet and some friends, I hope to get this done by mid-Summer. My modest garage that can barely fit the TJ in:

I also got a KICK *** differential cover from Ruff Stuff Specialties for the 8.8 ... this thing is stout with a 1/2" ring and a one piece (bent 8 ways) 3/8" thick cover. The cover was brand new (with some very minor surface oxidation) ... and costs $125 with countersunk bolt holes and 3/4" I.D. fill plug. So with that, I got the complete axle for $175.

Ruff Stuff cover on left, stock on right:

Cover off, checking to make sure of ring and spider gear quality ... no nicks, breaks, or loose metal in diff or fluid. I also cleaned the gasket surface:

Just a few pictures of the brake lines, calipers, and everything else for reference:

The emergency brake cable ends. There's a collar around the line that needs to be pinched in, then you can disconnect the cable from the lever and gently hammering the collar down ... the line and spring go through the hole and on out:

C2U5H · 02-28-2009, 04:32 PM

Keeping track of everything:

Admiring the Ruff Stuff cover on the diff:

Got all I could do for today ... cleaned up, and organized for the next time I get started:

The throw-away pile:

My only question is, what is this little guy right here?

Well, until next time!! I'll be grinding the brackets off, clearancing the ABS mount ears, cleaning it up, and spraying primer on to keep it from rusting up again.

~J

**alecmcmahon** · 02-28-2009, 04:35 PM

looks like the breather tube.

C2U5H · 02-28-2009, 04:37 PM

Quote:

Originally Posted by alecmcmahon

looks like the breather tube.

That's what I thought ... but wasn't the Explorer's breather tube out of the top of the differential? Works for me.

Greg_Volkman · 02-28-2009, 04:39 PM

that little guy is the breather tube. you can either weld it and drill a new one, or clearance you bracket like we did on mine:

Joe4 · 02-28-2009, 04:43 PM

Hey so you know I had a problem with my Riddler cover hitting my gas tank skid and that cover looks deeper than the Riddler, so just be aware as you set it up so the cover doesnt rub. I extended my wheel base as much as I could and barely have enough room.There are alot of good 8.8 writes up around to help if needed.
Have fun

Tim · 02-28-2009, 04:50 PM

i was going to mention gt clearance too.

i drilled and tapped a new breather location. the old one was plugged with a threaded slug and welded over. i just left the abs sensor on top of mine, some have welded a plate over this. i like it because its a easy place to add fluid.

**alecmcmahon** · 02-28-2009, 05:06 PM

i THINK the one on the top off the housing is for the ABS and other junk.

when i hooked up my breather tube i used the little guy on the axle tube.

didnt touch the ones on the top.

C2U5H · 02-28-2009, 11:37 PM

Quote:

Originally Posted by alecmcmahon

i THINK the one on the top off the housing is for the ABS and other junk.

when i hooked up my breather tube i used the little guy on the axle tube.

didnt touch the ones on the top.

Well yea, the sensor on the top is the speed sensor for the ABS.

I didn't know if the stock breather was the one on there or if the guy I picked it up from drilled and tapped it there. Guess this axle is 100% stock, which is great!

Thanks for the help.

BP88 · 02-28-2009, 11:57 PM

Great write-up so far!

I also like how you organize your little bits and pieces in Ziploc baggies like I do. lol

**TJamz** · 09-21-2009, 02:12 PM

Keep it comming!

02-28-2009, 04:35 PM	#3
alecmcmahon Web Wheeler Join Date: May 2005 Location: Woodbridge NJ Posts: 2,585 Profile Gallery Classifieds My Jeeps	looks like the breather tube.

02-28-2009, 05:06 PM	#8
alecmcmahon Web Wheeler Join Date: May 2005 Location: Woodbridge NJ Posts: 2,585 Profile Gallery Classifieds My Jeeps	i THINK the one on the top off the housing is for the ABS and other junk. when i hooked up my breather tube i used the little guy on the axle tube. didnt touch the ones on the top.