Ultimate XJ Build - Superduty Swap, 37s, Stinger, Rocktrac Swap, BDS Long Arm - JeepForum.com
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post #1 of 58 Old 02-19-2020, 12:47 PM Thread Starter
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Ultimate XJ Build - Superduty Swap, 37s, Stinger, Rocktrac Swap, BDS Long Arm

Starting point it was a mere baby

1994 Jeep Cherokee XJ Sport Automatic 4.0

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post #2 of 58 Old 02-19-2020, 01:00 PM Thread Starter
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We had a Dana 44 from a 1977 Cherokee FSJ so we had to retube the axle to get the diff on the proper side. Goodness that was not fun...LOTs of grinding and drilling and finally got the tube out....Got a sweet set of brackets and mounts for the XJ suspension mounting points. Took a week or 2 but now its ready to go!
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post #3 of 58 Old 02-19-2020, 01:05 PM Thread Starter
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While the axle work was being done we took a break and installed the front stinger bumper on the stock XJ...looks pretty hilarious for sure at this point!
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post #4 of 58 Old 02-25-2020, 06:50 AM Thread Starter
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Time to tear the stock Dana 30 and 35 axles and suspension down and clean it up for the new 8.5 inch BDS long arm and Dana 44s
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post #5 of 58 Old 02-25-2020, 07:07 AM Thread Starter
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Beginning to assemble the leaf springs and other parts for the BDS 8.5 inch long arm kit install...
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post #6 of 58 Old 02-25-2020, 07:12 AM Thread Starter
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Yes we found out the blocks are a TERRIBLE idea later on but this is the flow of how our build progressed. Later we use a Iron Man Fab shackle relocation XJAX kit and took the blocks ou...MUCH better. More suspension components being installed! Had to cut a few inches of the bottom of the front coils to get them to seat properly in our fabbed coil buckets on the front Dana 44.
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post #7 of 58 Old 02-25-2020, 07:18 AM Thread Starter
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Removing the stock NP231 Transfer case and replacing it with a junkyard find NP241OR from a TJ rubi...bolted right in with no changes...linkage and electronics are identical just had to splice 2 wires since the pug is different...HUGE upgrade
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post #8 of 58 Old 02-25-2020, 07:22 AM Thread Starter
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Rear end is together sans brakes and rolling on some donor waggy 6 lug wheels and tires...its a unusual Dana 44 rear axle from a 77 Cherokee FSJ as well with a Dana 20 transfer case so it is offest slightly which required us to run a special narrow muffler to avoid the driveshaft
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post #9 of 58 Old 02-25-2020, 07:29 AM Thread Starter
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Got the front end assembled and painted ready to GO! 4.27 gears and a Detroit will provide lots of trouble free wheeling crawl ratio at this point was set at 47.8 just shy of a stock Rubi automatic. Beginning the front suspension assembly and getting castor and other details ironed out takes time
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post #10 of 58 Old 02-26-2020, 07:56 AM Thread Starter
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Sliding the re-tubed Waggy Dana 44 front under the XJ and getting the control arms lined up. Looks sharp.
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post #11 of 58 Old 02-26-2020, 09:54 AM Thread Starter
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Had 37s on 6 lug wheels on my sons suburban at the time so we rolled them over for a test fit for fender trimming and now its time to get excited!!!!!
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post #12 of 58 Old 02-26-2020, 10:05 AM Thread Starter
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Got the new tires and wheels in 37/12.5/R15s loved the look of this size back in the day...so much rubber hardly anyone makes 15 inch wheel sizes now

1st version of the Ultimate XJ Jeep is almost done!
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post #13 of 58 Old 03-02-2020, 12:51 PM Thread Starter
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Flex test and hitting the road as a DD...4.27 gears work well around town...70 mph requires a downshift to pull hills but goes back into OD as soon as the climb is over...detroit lockers front and rear with stock shafts...
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post #14 of 58 Old 03-02-2020, 12:57 PM Thread Starter
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post #15 of 58 Old 03-02-2020, 01:01 PM Thread Starter
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