Axle swap advice wanted

[alwaysstuck]

Hi guys, hope someone can help with some advice.

I am planning on swapping out my axles to a dana 60 and dana 44 out of my 73 f250 into my 95 yj. It appears as though the axles are only 1-2" wider than my yj axles which is fine by me, it also appears as though the front end pinion lines up with my transfer case output pretty close.

So far, here is what I figure on doing, please tell me what I left out:

1) weld on new spring perches and shock hangers
2) change to sye eliminator output on 231c transfer and have old ford shaft shortened/lengthened to proper length
3) figure out how to rig up steering
4) longer brake lines and longer shocks

Do most with this conversion stay with 8 lug fine thread studs or is there an adapter to get down to a number that you could actually change in less than 2 hours on the trail.

Questions:

do I need to upgrade my master cyl.?
do I need a new front shaft?

will 3.5" spring lift, 5/8" shackle lift, and spring over on some beefy axle tubes give me clearance for 36" tires without rub?

Thanks for reading, your advice is appreciated.

Mike

[J.T.Woody]

Well, when going SOA, you gain about 5" of lift.
Combine that with the 4" of lift you already have...9" of lift. I would think that 9" of lift should clear the 36's, but if you rub you can either trim the stock flares, or get extra wide YJ/TJ flares. I'd suggest the TJ extended flares.

Your tires will be sticking out quite a bit past the flares, Mike. I'd say they will be sticking out a good 8" past the body at the minimum.

Sorry I can't help with the rest.

[alwaysstuck]

good point- another $250 I didnt budget for.
This is what I'm trying to figure out now, total cost--- after 2 lockers, 5 tires and rims, etc I'm over 2500 and a full weekend of labor...

I am still unsure if my motor can handle the extra weight and diameter of the big axles and big tires. My axles are only 410's- same as I have now and I'd say my rig is currently powered sufficiently to do 75 down the highway without working it. Now im (thinking outloud) considering if I do the axle swap, do I dump the 4.3 and go to a 5.7- that should be an easy conversion but also cost another 1200.

[bluerocket]

As for your 8lug fine thread question. Its probably cheaper to get OBA and an impact gun to zip them off than to convert to another lug pattern. Plus onboard air rocks.

[jps4jeep]

That set up sounds great but not at all practicle, even if it is a trail only rig. a SOA on stock springs will fit 36" tires Here is a pic of mine on 33's and my friends, SOA stock springs with 36" tires

This set up is a very good one.

Second, there has been no mention about putting a full width axle into a stock spring width YJ frontend. Won't fit. You will need some type of Full width front axle kit. Poison Spyder sells one, or you can try to fab one up, not all that easy!

Now back to the height, you will be able to fit a 40" tire with a SOA on a 4" spring, and again, this is over kill for just about any trails we use. also, you center of gravity wil be dangerously high. off camber situations will turn into up-side-down situations very quickly. also the springs will be very prone to axle wrap and will not flex all that great! What I would suggest, see if someone will trade your entire 3.5-4" lift for a 1.5" lift. straight swap! then perform a SOA with the axles you have, as well as a full-width front end kit. throw on some 37's and be done. If you want to up grade to 39" tires, I would simply start cutting the body out and use some TJ flares or Bushwacker flares.

A 1.5" spring will be less likely to have axle wrap (still will and this is something you will have to address with traction bars) also the 1.5 springs will flex a lot better than the 3.5-4" version. Also giving you a better ride.

Just my $.02

[alwaysstuck]

John,

My reason for considering a big lift with the axle swaps is because I figure a dana 60 pumpkin has about 3-4" less clearance than a dana 35 pumpkin and I dont want to be moving sidewards here.

I agree with your point about center of gravity- the ideal technigue is to keep the jeep low and the tires big. I have wheeled my buddies yj with a lot of lift and because the wider stance of the axles and the width of the full size tires (maybe 14-16") it feels (wether it is or not is another question) more stable than mine does with 33x12.5's and no offset on the rims.

As far as spring wrap, I have the boomerang shackles- and these seemed to help the jeep flex a lot more than stock shackles. I am figuring on a homeade track bar in the rear to keep twisting down???

Thanks for your advice, although I am still having trouble figuring out how your buddy runs 36's with only a soa lift. I figured removing the lower perch gives you 1", adding an upper perch gives you another 1" and an axle tube may be 4" round max, thats only 6" Can you run 36's without rub on a yj with only 6"? If so, I may do a body lift and trim some body and wait until i break an axle to do the conversion. Would a 35/30 combo with locker in the 30 hold up to 36's?

Also, could you clarify your second point about full width axle kit... what exactly is the kit for, what does it do, why is it required, etc. It's something that I know nothing about and should prob get familiar with before I go any further with my planning.

Thanks for your input, it is appreciated.

[bluerocket]

30/35 is definatly not reccomended for 36" tires, as a referance Littleredtj just broke a D35 with 33's.

[97Sahara]

Rubicon Express sells reversed leaf springs specially made for spring overs, they are 1.5" of lift on top of the SOA.

[SPYDER]

to address the master cylinder question...yes you will need a new one to handle the bigger brakes.

lift height does nothing for getting your pumpkin higher, only tires will do that...so i would strongly suggest getting some 1.5" springs instead of the 3" springs.

[alwaysstuck]

John, Hopefully you will read this post again, I looked at the fill width axle kits and I don't think I'd need one, but I'm hoping you'll correct me if I'm wrong. Although I need to do some more accurate measurements before I progress further, my pumpkin doesn't interfere with my spring location and these axles are around an inch longer on each than the stock. Putting the springs outboard of my frame would cut into my turning radius and cut down my wheel/spring travel range. If I didnt have to do this, I would prefer not to.
Furthermore, this post may be a waste of time because after dealing with the frustration and expense of trying to plan this conversion, it's seeming easier and cheaper to sell my jeep and buy one thats already built the way i want it.

[jps4jeep]

Don't give up so easy! your expecting too much too quick, planning is a huge part of the process! I have been building cars, both as a hobby and professionally for over 15 years, It takes time! For example, My Yj has been about 5 years in the making! and I am not even close to done! I have a set of D44's that are going to be going in, but It has been almost a year since I started just that particular project. I have been saving money, and buying parts, lots of them used, piecing things together. and eventually I will go from my 33's to 35's! Honestly these axles won't be finished for probably another year, my tires don't need replacing, and there is nothing really wrong with the stock D30/35 I currently have!

My advice, do more research! do more research than you think you will ever need!
For example, and don't make fun of me, when I find an article that I find useful on the internet, I simple print it out, and make it bath room reading! I also have a note book full of my ideas and plans.

It takes time! most of the people on here have been building their jeeps for years!

What is your current set up? I am gonna take a shot i the dark, YJ with a 3.5" lift and some 32's.. Just a guess! If I was in your situation, I would sell the 73 axles, and what ever else there is from the truck (You'd be suprised what the tranny and tcase is worth) and take that money and invest in a winch, OBA, upgrade your gears, front axles, toss a 8.8 or a XJ D44 in the rear, stuff it with a locker. you can more than safely run 35" tires on a semi stock D44/8.8 and modded D30!

[alwaysstuck]

John,
Pretty close on my jeep 33's on a 4" lift- already got a locker, already got a winch, dont need air (like driving down the hway on 12 lbs pressure- smooth ride), 411 gears are fine, maybe even too low for 33's

Already seen a d44 blow up with 36" tires- its sitting in my yard right now with a cracked case (I'll email you a pic) In the pic, see the jeep in the front, thats mine, it's little, see the jeep in the back, thats the one I wheel with, its big--- and I dont like using my winch, nice to have, but I dont like needing it.

No patience to make a jeep a 4 year project, I want to be able to ride through my back yard or anywhere else without getting stuck tonight, not in 2009. I wish I had patience but there is a good chance that by tommorow at this time the jeep will either be sold or have no axles under it. lol

[dsgray16]

"Would a 35/30 combo with locker in the 30 hold up to 36's?"

IMHO

If you have to ask that question you shouldnt be planing fullwidths with an SOA and 4 inch lift springs

sorry dont mean to sound harsh

[alwaysstuck]

ds gray,
I havent broken an axle yet and I see guys on 35's with 30/35 combo all over this site...Obviosly, I am trying to determine what kind of axle I will be needing.

if your intent is to be a non contributing , keep your comments to yourself or reply to someone elses questions.

[1BadTJ]

chill out everyone,

Your asking for advice or opinions, your getting them.

everyones opinion is different.

Everyone kiss and play nice