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ZJ Superduty front and rear axle swap part list and cost

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16K views 9 replies 4 participants last post by  Timo_90xj  
#1 ·
Hey everyone, after doing a few hours of searching it seems like i have not been able to find all the information i am looking for. I have a 1998 ZJ 5.2 with a 4" zone offroad suspension lift, full bolt ons and currently on 33" mud terrains but plan to use 35x14.50r15 boggers for the mud bogs. From what i have gathered the Dana 30 probably isnt going to last very long so i am looking into doing the 05+ superduty dana 60 front axle swap along with swapping in the rear 10.25 Sterling. While its probably not going to happen for some time i would really like to have the information and list so i can start acquiring parts when its possible. For those of you that have done the swap yourself what is the approximate cost you have into swapping the front and in the rear? Does anyone have or can list a complete parts list needed for the front and rear? Seems like the going rate for a complete used lower mileage 2005+ super duty dana 60 is $600-$800 and about the same for the rear axle. Then a ZJ dana 60 truss is around $500 and that as far as i was able to go on without knowing exactly what is needed. If anyone sells a complete swap kit please be free to link it. Any help or input is greatly appreciated!
 
#3 ·
The plan is to run the 35x14.50r15s for atleast a few years but eventually jump up to 37s. As far as power goes with full bolt ons it will be getting a wet nitrous kit and plan to spray a 100-150 shot. It seems the majority of the statements is the Dana 30 just isn't worth putting money into if your running 35s. So frame stiffeners, more lift (which it will be getting lifted another 2.5"/3" before i put the 35s on), long arms, truss and anything else you could think of? what about steering components? Seems like for the rear is pretty straight forward doing a basic 4 link setup? I am surprised with how popular of a swap it is there isn't any full write ups, part lists etc. on it (atleast not that i could find). Found alot of threads on doing it but nothing that had a breakdown on what is needed and cost.

Full frame stiffeners, more lift+long arms unless you plan on cutting and welding for clearance, bigger tires. People with tons usually run 37s and up.
You'll want long arms regardless. Short arms won't cut it for tons.

Sent from my SCV46 using Tapatalk
 
#4 ·
With that tire size, inteded use and power upgrades, I'd certainly look at 1- ton axles. D60 front, D60, D70 or GM 14b rear.

3-link front long arms or 4-link mid-arms ( = similar CA length as JKs), double triangulated rear 4-link would be my choice for control arm setup. Pirate4x4 has more info; I've got the 4-link calculator on my computer which has both front & rear on the same excel sheet.
Full frame stiffeners from front to at least all the way to rear coil/ shock mounts, box steel rockers properly tied to the unibody.

Doing these kind of mods to a uniframe full-body XJ, ZJ or WJ is honestly just plain stupid, but once finished it's well worth it ;) Everybody builds full size trucks and Wranglers.. :D
If I could legally use axles in the full size 1-ton spec. on 37s+, I would've had them in my ZJ for years now. Too bad the vehicle modification laws in my country don't allow that.
 
#5 ·
I've got a bunch of pictures of the uniframe mods I've done on my Jeep, some of them with text in the build thread link found in my signature (build thread sort of sucks now due to some of the earlier picture links being broken); pictures can be found here:

https://timolampi.kuvat.fi/kuvat/Of...uvat/Offroad/Auton+rakennusta/Tukivarren+kiinnikkeet+ja+koripalkkien+vahvistus/

https://timolampi.kuvat.fi/kuvat/Offroad/Auton+rakennusta/Etu-+ja+takapuskuri/

https://timolampi.kuvat.fi/kuvat/Offroad/Auton+rakennusta/Takanurkkien+vahvistus/

https://timolampi.kuvat.fi/kuvat/Offroad/Auton+rakennusta/Takakaarien+ja+-ovien+muokkaus/
 
#6 ·
Those pictures are exactly what i was looking for as it has really good detailed stepped pictures of the process and what needs to be done. That's no fun about the laws not allowing you to do what you want to YOUR vehicle! Here in the states every state has different laws but for example here in Michigan you can literally drive just about anything. There is laws on the books for lift heights and exhaust systems and what not but its never enforced. What did you end up doing for the steering setup on yours?
 
#8 ·
Nice custom fabricating!

I see you're running

1) wheel spacers
what are the specs? thickness? Are they still 5x4.5 (or now 5x5)

2) 16" rims
aftermarket? aluminum? What is the backspacing?

3) BFG 285/75/16
any reason not staying with stock 15" rims?

Are the frame stiffeners from IRO?

What rear axle, transfer case, front axle?

Is there a writeup somewhere?

Do you actually need the rock sliders in Finland?

You need to move to western USA, for rock crawling


^^^ upgrade to 1 ton axles (from full size)