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Discussion Starter · #21 · (Edited)
Quick turn around on the oil leak and had it running the next day to take to River Rock on the weekend.
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Went with the Ft Stewart Military Jeepers, which brought out a handful of JKs, Gladiators and TJs, and really went everywhere in the park, because there are some many bypass trails and optional lines everywhere.

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The only issue I had was the pressure fuel line came apart at the firewall between the hard line and soft line to the engine. I need to replace the double hose clamps with a proper fuel line fitting to ensure it stays together.

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Discussion Starter · #22 ·
I found this used Dana 60 rear built for a CJ. It's an older Ford D60 high pinion diff with big bearing 9" semi float 35 spline shafts, 4.10 and Detroit locker. I like the narrow width and high pinion; now to decide if I'm going to link the rear or keep the SUA leaf springs.

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I think with that heavy of an axle your probably gonna have to link it. Could be wrong but I believe they like to eat leaf springs if your into rocks.
 

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Awesome build!


You wont have any issues with leaf springs in the rear as long as you add an antiwrap bar. Im running a 14bolt with XJ leaf springs in the rear of my YJ with no issues
 

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Discussion Starter · #25 ·
Alright; 1 vote 4 link, 1 vote leaf springs. lol

It really will come down to how much project to do I have time to endure. I could swap the 8.8 with D60 no other changes in one day, or I could build link mounts, build links, coilover mounts, fuel cell, driveshaft stretch, rear wheelwell stretch….might take longer.
 

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Discussion Starter · #34 ·
I got started today on the Barnes4wd rocker guards. I knew they would be long with my aftermarket front fenders, so I sized them up for trimming.
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A paper cutout for fitment, then transfer to metal and slice with the plasma.

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The rear cut was less exciting with just an angle cut off to match the flare. I unbolted the drivers body mounts, jack up the tub and slid it in place for drilling.


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I did get all the holes drilled, but then pulled it off for paint. And that’s where I’m at tonight. Maybe finish tomorrow.
 

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Discussion Starter · #37 ·
I got real impatient with the old 8.8 open-diff pinion-howling rear axle and decided to swap in the Dana60. I'm not ready to link it yet, because I want to stretch the wheelbase and coilovers and links are expensive. So I cut out some leaf spring perches and set up the axle with even more brackets than it already has.

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I tried to slide it back a little to gain forward clearance in the wheel wells, but ran into a 20gal limiting factor.

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Discussion Starter · #38 ·
I pulled the gas tank today and set the pinion at ride height.

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I then tacked the perches in place, pulled the axle and completed the welds. I also added shock studs to the u-bolt plates. The bolted the axle in place, back 1.5” on the centering pins.
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Discussion Starter · #40 ·
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This Motobilt fuel cell showed up over the weekend. It replaces my junk skid plate and adds a bunch of room the bigger diff that’s also 1.5” back leaf spring pins.
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I kinda like these fuel cells.

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