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CONVERSION INFO: This
article is based on my experience and advice concerning a Ford Explorer
8.8" rear axle swap into a Jeep Wrangler (YJ). First of all, if you're
reading this article, you are probably a fellow Jeeper running a Dana 35C and
are in desperate search of more strength and durability... Well then you came to
the right place. This axle swap was my first, and as far as I'm concerned, a
very easy do-it-yourself type of swap. If you can install a lift kit you should
have no problems swapping an 8.8" into your Jeep. I will start by telling you my reason and
plan for doing my 8.8" swap. First of all, I planned on doing a SOA (
Spring-Over Axle) Conversion and when doing so I read many articles and everyone
seemed to believe that if your going to go to this type of conversion you may as
well swap in stronger axles while your at it. After looking at several options
and not wanting to spend too much money, I thought about a Ford 8.8".
I figured it had to be fairly strong considering Ford puts them in there
Mustangs, Explorers, 1/2 ton fullsize trucks and some Expeditions. I did some
calling around trying to figure out the total length of this rearend. I'm not
positive off hand, but I think that the total length was 59 3/4" from side
to side, give or take a 1/4". A stock Jeep Wrangler Dana 35C is 61
1/4", which would only pull my tires in about a half inch on each side.
Since I plan on running 35" tires or bigger this won't be very noticeable. Since nobody, to my knowledge, was trying
this swap at the time, I pretty much had to figure it out by myself. I first
called around trying to find an 8.8" which was from a '95 to newer Ford
Explorer, because after '95 Ford changed over to disc brakes. The '95 and newer
were also factory equipped with 31 spline axle shafts. The pre-'95 8.8"s
came equipped with a weaker 27-spline axle shafts. I called around and found a
wrecking yard that had one from a '97 Explorer and wanted $450.00 for it, which
I thought was a good deal. I went down there, picked it up, and brought it home.
I cut all the old brackets and mounts off so that the axle tubing was smooth and
ready for my new mounting brackets. Luckily, I didn't have to change the brake
pads; they were still almost new. The rotors were in perfect shape, so those
also remained factory. Anyway after grinding/cutting all the old mounts off, I
went ahead and re-painted the axle. I like to use semi-flat black because it's
not too dull and not too shinny. There is a suprising size difference between
the Dana 35C and the 8.8". You'll see, just wait until you set the Dana 35C
next to the 8.8", it makes the Dana 35 look like a golf cart axle. Anyway,
I got all my SOA conversion stuff together and 8.8" rearend ready. On a
Saturday I decided to install it, I finally had everything ready. It took about
6-8 hours for the complete SOA and rearend swap. I performed all the welding and
everything related to the conversion with the help of one of my Jeep buddies. I
highly recommend having someone assist you when performing this swap. The
pictures below are taken after the complete installation. (click on pictures for large view) 
 UPDATE INFO: Its been about a year now since my
conversion and the 8.8" is still holding up. I've since added 4:10 gears
and a Detroit locker thanks to Hicks 4x4 in Pomona California. I made a good
deal with Hicks 4x4. I offered to trade my old Dana 35C for the cost of
installing the gears and locker. At the end, all I had to pay for was the
Detroit locker. I can honestly say I've never had one problem with my 8.8"
since the swap. I highly suggest this axle conversion to all Jeep enthusiasts
that are in search of a stronger, more dependable axle. Below are some
specifications I've gathered regarding both the strength of the 8.8" and
Dana 35C. '97 FORD Explorer
8.8" Rearend Specifications. Donor Vehicle = '97 Ford Explorer Factory Gear Ratio = 3.73 Axle Shaft = 31 spline Axle Diameter = 1.32" Ring Gear Diameter = 8.800" Traction Action = POSI-Traction Brakes = Disc Brakes Axle Strength Each = 6,500 lbs. Before breakage Total Length = 59 3/4" Axle Tube Diameter = 3.25"
90 JEEP Wrangler Dana 35 Spec's. Factory Gear Ratio = 3.50 Axle Shaft = 27 spline Axle Diameter = 1.16" Ring Gear Diameter = 7.560" Traction Action = Limited-Slip Brakes = Drum Brakes Axle Strength Each = 4,000lbs. Before breakage Total Length = 61 1/4" Axle Tube Diameter = 2.5"
PARTS LIST: -'97 or newer ('97 till present have Disc brakes) Ford Explorer 8.8"
rearend ( Not a Ford Ranger 8.8" they're much shorter around 54" -
56") -Driveshaft Adapter (SPICER PN 2-2-1379) - Lokar Brake Line Adapter (I never needed to use this, but recommended) - Custom E-Brake Line Adapter - Spring Perches - Shock mounts
OTHER: Granatelli offers a really nice heavy duty differential cover. The cover
sells for $149.99 (click on image below for large view)  |
Posted Nov 24 2007 11:33AM
