Axle swap on 1996 xj

[Markus2001]

So I can get a front and rear axle out of a 95 xj which is a 4.0 automatic. Mine however is a 96 4.0 with a 5 speed and 3.07 gears and auto is 3.55. 5th gear is about useless because of way it's geared I'm all stock and plan on staying stock so was wondering besides the axle what else is needed swap I heard something about gear in transfer case for speedometer. Both are dana 30 front an 8.25 rear

 

[Anak]

Yes, you will need to change the speedometer drive gear. There are tables to tell you which color gear you want depending on gear ratio and tire size.

Get new U-bolts for the rear (Or, if the leaf springs are good in the '95, don't separate them from the axle). Unless you have replaced your front bumpstops now would be the time to put in new ones. Seriously consider replacing the UCA bushings in the front axle before you swap it in. Those are much easier to access with the axle out of the vehicle. If you can weld it would be a good idea to add some reinforcement to the passenger side UCA tower.

You probably want to swap the front axle shafts from '96 D30 into the '95 D30. I think '96 was the first year of the larger U-joints. Spline counts are the same. It is just a matter of swapping the shafts from one axle to the other.

 

[maxbraketorque]

...

You probably want to swap the front axle shafts from '96 D30 into the '95 D30. I think '96 was the first year of the larger U-joints. Spline counts are the same. It is just a matter of swapping the shafts from one axle to the other.

I think '95 is partial old style and new style axle shafts for the D30. The '95.5 D30 I put in my 2000 XJ had the same axle shafts as was in my '00 D30.

Note that when swapping between the two styles of front axle shafts, the brake rotors also need to be swapped because the offset between the brake surface and the wheel mounting surface is different. Or just buy new rotors for the later model.

 

[Anak]

Note that when swapping between the two styles of front axle shafts, the brake rotors also need to be swapped because the offset between the brake surface and the wheel mounting surface is different. Or just buy new rotors for the later model.

Are you sure about that?

I thought the rotor change was about unit bearings.

 

[maxbraketorque]

Are you sure about that?

I thought the rotor change was about unit bearings.

You may be correct about that. I suppose that means the OP may want to consider whether he uses the '95 unit bearings and rotors or the '96 unit bearings and rotors.

 

[Anak]

I don't think there is any difference between '95 and '96.

I think it is only the last couple years of the late models that got the different rotors and unit bearings (those would be the unit bearings needed for the WJ brake swap).

 

[Goose_XJ88]

Agreed, If memory serves me right, there are 3 different offsets of unit bearings/brake rotors. Renix 87-90, HO 91-99.5, and HO 99.5-01 (XJ) or 06 (TJ). I dont have any idea on the early AMC 84-86 years.

The renix I am not 100% sure but I do know they have 2-piece knuckles and I believe different brake calipers (they use allen head bolt vs standard bolt)

 

[maxbraketorque]

I looked up my notes, and indeed the unit bearing and rotor change were between 1999 and 2000. Bigger u-joints are '95.5+

 

[Tim_MN]

XJ D30 hub, rotor, caliper, axle shaft interchange info >>https://naxja.org/threads/front-bea...re-but-checking.1057638/page-2#post-245269210

 

[Anak]

Excellent information.

Thank you Tim.

 

[Goose_XJ88]

I looked up my notes, and indeed the unit bearing and rotor change were between 1999 and 2000. Bigger u-joints are '95.5+

Bigger joints were also in earlier ABS jeeps.

Another less commonly known fact is that Renix era XJs with a 242 have non-cad axles

 

[FusiliJerry]

If he were to get a Vanco Big Brake kit with their "universal knuckle", can he use their pre-machined 99+ unit bearings? If so and there is a want for better brakes now may be the time to pull the trigger. I wish I had done so before I installed BCA stock replacement bearings without a means of machining them myself as necessary to a satisfactory precision.