Who in their right mind would take a perfectly functional
9-year-old Jeep YJ, rip out the entire undercarriage, and replace it
with parts from a 25-year old Ford? Chances are if you're reading this
then you understand already, but for those of you who don't...
Stock YJ axles are a relatively weak link in an otherwise
excellent vehicle. If you want to run tires over 31",
especially with lockers, then the odds of breaking an axle shaft
or u-joint, or even bending a housing, go way up under even
moderate usage.
The early Broncos, on the other hand, were big, heavy, and thus
very solidly built. The stock axles for a 1973 EB were a
standard-cut Dana 44 up front and the much-praised Ford 9" in
the back. In a YJ they make for a very stout combination and
reduce the odds of breakage even with large tires and lockers.
The brakes are bigger all around (I've ended up with 11"
discs and 11" drums). The axles are about four inches wider
than on the YJ, which is nice for a little extra stability too.
It was a cool project. Early on in the game I discovered that I
couldn't find anyone who had ever done this swap before, so from
then on it became a personal challenge. Something about the risk
involved appealed to the fool within me. That and I had no idea
what I was really getting into. My most ambitious project before
this was an on-board air system (not even in the same ballpark)
and while I'm mechanically inclined this was way beyond anything I'd ever done before.
How did it start?
Before the swap, My Jeep was a relatively stock 1989 YJ. It had
2.5" OME lift springs in it and 31" AT tires, and that was
as far as I thought I wanted to go with lift. Then Larry Soo (aka lars)
got involved. I remember one conversation:
Larry : "You should do a springover. Hmm... springover with
OME springs." Me: "Uh, yeah, right. Heh heh."
But the seed was planted. I'd wanted to get a rear locker for a
while, but didn't like the idea of throwing $$ at the stock D30 and
D35 axles after hearing them bashed so often on the Jeep-L and
Jeeptech lists.
Some time later, Larry told me about a friend of a friend who was
selling a pair of axles from an old Bronco. I went over to see them.
They looked terrible! Covered in rust and some kind of green mildew,
but the potential was there! The rear end had the stock 28-spline
axles, and the front had a standard-cut diff and drum brakes, but the
width looked good and they had 4.10 gears in them. Next thing I know,
I've purchased the axles and I'm planning a spring over axle
conversion.
Ford 9":
Preparation and installation of the Ford 9" rear from an
Early Bronco into a Wrangler YJ. The Ford 9" is massive
compared to the stock Dana 35c.
Dana 44:
The early Bronco Dana 44 had 30 spline shafts, 8.5" ring
gear, and real hubs. There are many advantages of a Dana 44
front end in a Wrangler or CJ.
Spring Over:
Doing a spring over conversion on a Wrangler YJ for maximum
articulation. The conversion is a bit more work than a normal
lift, but the results are amazing.
Final
Notes: Some final notes on the spring over axle swap and
early Bronco axle swap. Important things like wheel bolt
patterns must be considered.
Need Gas Mileage & Power?- Free flowing performance exhaust can
increase gas mileage and increase power. We can all benefit from increased mileage and increased horsepower & torque
improves towing, mud-slinging and the ability to turn those larger tires you put on your truck. See what Flowtech
Exhaust has for your gas or diesel truck.
Off-Road Videos - Check out over ten years of extreme 4x4
action,
product testing and the Off Road Nation at play. Baja racing to rock crawling, ATVs in the sand to motorcycles in the
dirt, it?s all here. Rate them, share them and upload your own.
ATV Reviews - Honda, Suzuki, Yamaha, Polaris, Kawasaki,
Can-Am. First rides to long-term tests, check out the latest in ATVs, UTVs and Side-by-Side vehicles of every make and
model. Read expert opinions and follow custom project vehicles.