Got some new beef--'01 XJ 8.8 (56k killer)

[Silver60th]

So, after I annoyed everyone asking questions about the 8.8, it's finally in! It took about 1 week from the time we picked it up until it was in. Would've been a lot quicker but we only worked during the evenings on it. And we live 25 miles from town so parts runs were frequent and extended. Bear with me, these pictures were all taken from my phone.

My specs are as follows:

2001 Jeep Cherokee 4x4
NP231
AW4
D30/D35(Now 8.8)
2.5'' pieced together lift
255/70/16 Treadwright Pumas on Soft 8's

The axle, straight from the junkyard with 4.10's and a limited slip, 44k miles, $185

This tag makes me happy

Padre torching shock mounts off of D35

Mopar spring perches being fitted on the axle tubes ($18 btw)

....and welded

http://s246.photobucket.com/albums/...on=view&current=Photo0022.jpg&t=1280802302501

Tubes welded. Use a high nickel rod, heat the differential housing and tubes around the weld evenly, and cool evenly or the cast will crack. (these next few pics were taken after the install at night...forgot to take them during)

E-brake setup

Driver's side brake setup- used stock Explorer lines for the entire axle.

Brake hose extension to connect to frame from Explorer line

And done!

Overall it was a very interesting build. I learned quite a bit during the whole process. If anyone wants any part numbers or has any questions, feel free to post up and ask. I will try to answer everything I can.

I ended up reusing the explorer u-bolts and u-bolt plates with a little trimming.

:compwork:

*EDIT* I realize the last few pics at night are pretty terrible, I will try to take more tomorrow.

 

[Silver60th]

Slightly better pic on how the stock e-brakes attach

 

[XJTAO1]

It look great! Keep me post to see how it treat you on trails.

 

[Silver60th]

Will do XJTAO1.

Right now we are trying to figure out why the differential is being noisey...the gears and spiders all looked great, and we put the LS additive in. We used 85w140 synthetic blend since we couldn't find the 75w140 full synthetic that it wanted. Maybe things just need more time to get lubricated? The axle was sitting for a while.

Any insight?

 

[kastein]

How'd the bearings look? What kind of noise is it making, clicks and clunks or grinding/rasping/droning noises?

 

[REWSTER]

Looks good, thanks for the wright up i have been tossing the idea of this swap around in my head and this would help

is it necessary to weld the tubes or is that just for the extra beef factor?

 

[kastein]

Definitely necessary. Ford saw fit to retain the axle tubes with some hammered-in metal plugs - I wouldn't trust them to stay in. I've seen them blown out and the tubes spun in the junkyard, still under explorers.

 

[REWSTER]

i will have to keep that in mind if i wanna do the swap or not, i dont have a welder so i would have to get someone else to do it

 

[Silver60th]

As far as the noise, it's more of a grinding/droning noise. It's not present until over 15mph or so, and then steadily gets a little louder. Not major at 70, just present. Whenever I let off of the gas or step on the gas, there is a momentary louder grinding noise.

I'm thinking its the pinion bearings, but I don't know. The axle itself only had 40k miles on it, and still had oil in it when we bought it. We did add the limited slip additive. I'm really hoping it's something cheap and simple but who knows. Either way, I'm going to run it like this for a while. Should be ok for the time being.

 

[kastein]

Sounds like pinion or carrier bearings to me... maybe you got lucky though. Does it get louder when you corner? Louder on a specific side? If so you can try doing the carrier bearings.

 

[Silver60th]

It almost sounds like a ratcheting sound, especially when I slow down to a stop.

Maybe the clutch packs are bad in the limited slip?

 

[SteveT]

Urban camo? I kind of like this look.

 

[privatejoker]

These use a drum inside the hat, correct? What was the condition of all the e-brake hardware?

 

[Silver60th]

The e-brake hardware was ok. We had the brake surfaces for the regular disc brakes and the e-brakes resurfaced.

And the urban camo was a junkyard year-model special. Yellow for the particular series
And that rust was custom applied, and carefully crafted

 

[jeeperjohn]

The rust look is cool but most people overdo it