Installed the Ford 8.8 rear axle...

[cewtwo]

What a lot of weekend work. A case of the blind leading the blind. Removed the old axle fairly easily. Couldn't get the track bar off so I cut it off. Didn't plan on keeping it anyway.

Installed the new axle and marked the locations of the spring perches and the shock mounts. Checked pinion angles then removed it again to do the welding. Got it in, the brake lines mounted and the tires on. Used boomerang hangers in the back to mount the leaf spring and keep it off of the frame.

Our code enforcement division is very active. I don't have a garage, so all work has to be done on the street, and tires have to be on it overnight or they'll ticket it as an unsafe vehicle.

All that has to happen now is the drive train attachment, mounting the armored diff cover, final brake install, emergency brake install, shock install, and the field test. I should be ready for that by Saturday morning.

Phew! My back is killing me this morning, though...

 

[Bounty__Hunter]

Cool, in the middle of installing D44's myself. What fun :twisted:

 

[90Xjay]

What a lot of weekend work. A case of the blind leading the blind. Removed the old axle fairly easily. Couldn't get the track bar off so I cut it off. Didn't plan on keeping it anyway.

Installed the new axle and marked the locations of the spring perches and the shock mounts. Checked pinion angles then removed it again to do the welding. Got it in, the brake lines mounted and the tires on. Used boomerang hangers in the back to mount the leaf spring and keep it off of the frame.

Our code enforcement division is very active. I don't have a garage, so all work has to be done on the street, and tires have to be on it overnight or they'll ticket it as an unsafe vehicle.

All that has to happen now is the drive train attachment, mounting the armored diff cover, final brake install, emergency brake install, shock install, and the field test. I should be ready for that by Saturday morning.

Phew! My back is killing me this morning, though...

Man, you did that on the curb of your street?

Holy backache Batman!

I've never heard of ticketing you for not having a tire on. :shock:


Aren't the 8.8's one inch narrower? some folks just use a wheel spacer unless they are planning a wheel change and get a different offset.

did you replace a D35?
With the hectic schedule I figure you didn't have time to document the swap with pics? We need a good tech article on that one.

 

[Bounty__Hunter]

The 8.8 is slightly narrower than the D35, nothing to worry about unless you're anal about track width. I had to use different wheels with less backspacing when I put the 8.8 in my MJ, not that it was too narrow, but the stock rims hit the 8.8 brake calipers.

 

[cewtwo]

Actually, the real problem was not having all of the correct tools. I finally went out and got a 7/8" deep socket and an open/box end wrench and cut out endless time under the chassis laying on my back feeling extremely fatigued working with an adjustable wrench.

Yes, I did take pictures. From order arrival to installation. The plan is to write a technical article.

I reversed the shackles on this axle mount. Getting everything straight to determine the spring perches was the most fun, so far.

I was afraid with the Kilby Gas tank skid plate there would not be room for the Iron-clad pumpkin cover that I bought, but it went in with plenty of clearance.

Even bought an ARB locker for it. Watch those discount internet places. Got an excellent price ($705) but (after 20 + days) I still haven't received the locker. My Moab trip may be done with what I have instead.

Always fun with every project!!

 

[cewtwo]

The axle is narrower, but I haven't had a problem yet. Everything is centered and the brakes work.

I live 1 block North of Swedish Hospital, a major trauma center for our area, so Code Enforcement wants everything looking "nice." Our block is a restricted parking area.

I am planning on running it over at CORE this weekend (CORE is a front range pay-to-ride off road area). Everything else is still closed due to heavy snow this year.

I am taking extra u-joints with me until I can get the angles correct.

I have a back yard work area, but it has my RV parked in it. I might mention that I have not used the RV since I got the Mighty YJ...

 

[Bounty__Hunter]

I reversed the shackles on this axle mount. Getting everything straight to determine the spring perches was the most fun, so far.

I didn't understand this part. What you mean "reversed the shackles"?

 

[cewtwo]

I got a shackle reversal kit from Dynatrax, I think it was. There is a lower flat mount with custom shackle bolts and an upper that the bolts thread through. That allows the bolt ends and the nuts to be on top of the axle as opposed to below it. THAT was an extra amount of money...

Here is a picture that show it...

Now! As far as the project goes, everything was finally finished (except for the emergency brake cable - details). Bled the brakes this morning. I took it on a test drive after. It did most excellent!

I'll hook up the emergency brake cables tomorrow and take it to CORE (a commercial off-road center) this weekend. http://www.coloradooffroadextreme.com/

after that I will start on the technical report.

 

[cewtwo]

Just in case some of you want to see some of the additional pictures -

I cut the spring perches down to get that extra 3/4" clearance that I was after. I could not find spring perches for the reverse shackle design so I spent quite a bit of time getting to know my bench grinder better...

Installing the brakes. This picture also shows the top of the reverse shackle design. The leaf springs are new but are replacements for the BDS spring that I found cracked in two during my last Moab run. The ARB locker did not arrive in time for installation. Had trouble with the supplier (money was taken from my account but no locker for 3 1/2 weeks). I have a tracking number that shows it to arrive tomorrow (maybe next weekend to install that)!!

The Ruff Tuff differential cover (1/2" thick armour plate) and my well used and abused Kilby gas tank skid plate cover.

The almost finished back end...

The "Surprise" addition for those following me on the trail...

I will need to spend some time with the Kilby gas tank skid plate. The differential cover will wear against it at flex. I'll have to drop it and bend it in at the back in the area of the differential cover.

So... What do you guys think? (My friends do look at it and tell me, "Be afraid. Be very afraid!)

 

[TwistedCU]

When I hear shackle reversal, I think of moving the front leaf spring's shackles from the front side of the axle to behind the axle. That's done for approach angle and ride quality.

What you have there is a "U bolt flip". I'd like to do that on my YJ.

Your "Mighty YJ" just keeps lookin' better and better!

 

[90Xjay]

Your "Mighty YJ" just keeps lookin' better and better!

:agree:

 

[redrooster]

Yep, that's a u-bolt flip. The shackle is the piece (or two pieces) of steel that mount the spring to the frame on the flexible end.

 

[cewtwo]

Well, I field-tested it this weekend. Overall it did just great. There is a little vibration as the Mighty YJ decellerates so the pinion angle is not absolutely correct. I doubt that I will change anything until I get the new leaf springs to sag. The Ruff & Tuff armored diff cover did take some hits on Carnage Canyon in the Boulder area yesterday -

I think the morale is - Don't use white primer...

I am concerned about the Kilby gas tank skid plate. As you can see from the picture the pumpkin cover and the gas tank skid plate do touch.

Should I be concerned or just wait for the leaf springs to sag to a normal condition?

 

[cewtwo]

It snowed in Colorado last week, so I did not head down for "The Ol' Farts" run on Chinaman's Gulch near Buena Vista.

Instead? I put the ARB Locker in the Ford 8.8 axle.

That can be a lot of fun all by itself as you have to backtrack a lot. Tires off, brakes off, pumpkin cover off (helps to drain it first), pull the c-clips, remove the axles, etc. etc.

It was fairly easy to install once the axle was ready for the locker. I had already run the air line and set it up on the air manifold.

Pulling the ring gear was almost as much fun as installing it on the new ARB.

You'll find obvoius errors in this picture as I forgot to take another one before I put the cover back on. Had to cut the slot to allow for draining the passenger side axle oil. I thought that would be a difficult task, but it was fairly easy. A flat metal file, a rag stuffed into the axle and a few minutes labor!

Routing the internal air line was easy. Drilling the hole in the upper part of the pumpkin was much more of a challenge.

Setting the shim pack took a little more math than I was comfortable with, but I got excellent results (even though close friends eventually quit answering their phones).

I made sure everything was in, set correctly and closed the cover. By that time it was getting quite cool on Saturday night. The diff oil I used was suddenly thick and slow. It poured like a very slow molasses. It seemed to take forever to get that stuff into the pumpkin.

Sunday, I worked on the wiring. You know, there is only so much room in a YJ to add extra wiring. I worked up a small metal box and mounted it under the dash.

Once I find a way to mark the controls in the cab, I'll post that up as well...

 

[currupt4130]

Very nice.

 

[mingez]

I've never heard of ticketing you for not having a tire on. :shock:

Yeah..they are NAZIs out here!!! It's insane. The ticket enforcement is like no other city I've ever lived in....including San Francisco, San Jose, Oakland!!!!

I got a ticket for not have a front plate on my old miata (which incedentally didn't have a place to put a front plate) on Christmas day noon. :roll:

 

[mingez]

I will need to spend some time with the Kilby gas tank skid plate. The differential cover will wear against it at flex. I'll have to drop it and bend it in at the back in the area of the differential cover.

So... What do you guys think? (My friends do look at it and tell me, "Be afraid. Be very afraid!)

Finally a COOL graphic on a diff cover. I LOVE IT! 8)