Old Blue

[xjtrailrider]

I bought "Old Blue" from Steve's(Fitch) brother and drove it home from MD about a year ago. It had a nice RE4.5 super flex lift, Safari Snorkel, 32x11.5 and a bunch of mechanical issues.
http://img292.imageshack.us/img292/654/oldblueub2.jpg

I began the build by swapping axles and T-cases from Big Red and then swapped recovery and skids. I later added shackle relocation brackets and RE drop brackets/ACOS spacers.

Here are a bunch of pics!

Mechanical repairs
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/2.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/1.jpg

[xjtrailrider]

Axle swap
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/5.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/6.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/7.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/14.jpg

[xjtrailrider]

Shaving the 8.25 and raising the shock mounts
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/12.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/13.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/16.jpg

[xjtrailrider]

Detours sliders/stiffeners
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/18.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/19.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/20.jpg

Longer E-brake cables for the extra lift
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/22.jpg

[xjtrailrider]

Drop brackets and ACOS

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/46.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/47.jpg


Relocation brackets
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/27.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/41.jpg

[xjtrailrider]

Trail gear and tool box
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/24.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/25.jpg

[xjtrailrider]

As it sits now

http://i418.photobucket.com/albums/pp266/xjtrailrider/bobcat/1-09-2.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/bobcat/1-09-5.jpg

Whats in the future?

I'm building another 8.25 that will be geared 4.88 and have an Aussie locker/alloy shafts. I'm also building a D-30 that will be geared 4.88, Aussie locked, and have Longfield shafts. I also plan on installing a TeraFlex 2-low kit.

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/44.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/45.jpg

[xjtrailrider]

I'm saving my pennies for these little beautys!

http://rcvperformance.com/store/catalog/product_info.php?products_id=38

That should polish the turd to a brilliant shine!

[xjtrailrider]

Got another new cat installed last week, the high flow that was on there came apart, rattled and threw a CEL. I had Roberts put on a OEM replacement and all is well.


The Longfield axle shafts are on order for the D-30, no more broken front shafts or popped ball joints for me :p

The change over for the site starts tomorrow and I still have not decided if I will join right now. I'm a member of several different off-road clubs and organizations so I'm trying to see what I will do. If I'm not on here after tomorrow then I enjoyed it and I'll see you on the trail sometime.

Trailrider-out

[YJeXtreme]

Psst We're not going to run you out on a rail if you don't join up. I too am member of several clubs, so all is good :2thumbsup:

[RUkered]

I just saw Old Blue, leaving Dairy Queen. I thought about introducing myself, but didn't want to come across as, "Durrrr - hey I kind of know you." lol.

Rig looks great man. :thumb:

[xjtrailrider]

I just saw Old Blue, leaving Dairy Queen. I thought about introducing myself, but didn't want to come across as, "Durrrr - hey I kind of know you." lol.

Rig looks great man. :thumb:


Thanks! You should have said hello, I was just getting some ice cream with my youngest and oldest sons.

[xjtrailrider]

The parts are piling up!

Whats in;

D-30 3.73+ carrier
Yukon 4.88's for the D-30
Master install kit for the D-30
Rusty's D-30 truss
Nitro Gear 4.88's for the 8.25
Master install kit for the 8.25
Aussie locker for the 8.25
RuffStuff specialties axle truss for the 8.25
Front and rear axle housings

What I'm still waiting on;

Longfield front shafts, I'm giving Bobby a call today.

[hadfield4wd]

Longfield front shafts, I'm giving Bobby a call today.

Can't wait to see these.

[xjtrailrider]

Can't wait to see these.

Me too!!!

I'm fixing the persistent and nagging oil leak today. It turns out the front cover (timing cover) gasket was blown right next to the alternator. The 3 bolts that have studs on them for the alternator bracket were left loose at one time or another and the gasket blew out right there.

To get to this, I had to;

remove radiator
remove mechanical fan and electric fan
remove belt and pulleys
remove alternator
remove harmonic balancer
remove timing cover
remove starter
remove tranny lines
remove oil pan

What a PITA! I hope this fixes it and I do not create another leak in the process.

What a way to spend a day being "laid off" from work!

[xjtrailrider]

The persistent leak is fixed (for today anyway!) I could have pulled the engine quicker than what it took me to remove and replace/repair all of that stuff!

I talked with Bobby (Longfield) today and it seems my shafts should have already been shipped. He was going to call RCV and get after them to see whats up.

Hopefully I will have those little gems in the next few days.

[FitchVA]

Hopefully I will have those little gems in the next few days.

didn't i hear you say that a week or more ago? :rotflmao5:


:D i hope you get 'em soon. i'd be irritated if was getting jerked around like you are on those shafts

[xjtrailrider]

didn't i hear you say that a week or more ago? :rotflmao5:


:D i hope you get 'em soon. i'd be irritated if was getting jerked around like you are on those shafts

Yes, I'm getting irritated but the good news is they have not charged my credit card for them yet!

[xjtrailrider]

Craigslist score!

I picked up an old WARN Belleview (8000#) winch today for $150. Its basically the fore runner to the 8274 and is cable operated but can be up-graded to electrical controls. This thing is as old school as I am!

The good; It works and has a new motor and good cable. It holds 150' of 5/16. The "Belleview" is known worldwide for durability, no solenoids to give out. I got the cable controls and contact with it.

The bad; The Belleview does not reverse out, no biggie for me. The cable's for the actuator are too short for the XJ so I'm going to try to come up with some replacement cables or get creative.

I don't have pics of mine yet but here is a post with some pics and tech info from Ihatemud.com

http://www.ih8mud.com/tech/oldwarn.php

[hadfield4wd]

Nice score.

[xjtrailrider]

Another week passed and still no shafts:mad:

I sent RCV a nasty e-mail and told them I need them this week or I'm going to go with CTM's

Over 30 days now and 3 BS phone calls from Bobby and RCV, they can't be that busy with the economy the way it is.

[xjtrailrider]

I started the tear-down and rebuild of my winch today. Its in great shape but was put together wrong by someone before me, thats why it would not disengage. I ordered all new bearings and a new brake band for it today and should have it back together in a week.

I will begin work on my axles today.

[hadfield4wd]

Jon,

I was thinking about that winch today. Theorhetically you can get power out if you reverse polarity on the motor, which is just switching the leads. I wonder if you could do this with a big switch?

[xjtrailrider]

Jon,

I was thinking about that winch today. Theorhetically you can get power out if you reverse polarity on the motor, which is just switching the leads. I wonder if you could do this with a big switch?


If the motor was a "2 pole" I could do that but it grounds through the case and the frame right now. Also the motor has a "sprag" on the end of it to keep it from reversing.

RCV e-mailed me back today and promised my shafts to be shipped this week or they will give me a pair of their billet D-44 U-joints for free. I don't know what damn good those are going to do me but if it makes them feel better:D

[hadfield4wd]

Well stick them in your spare shafts. When you finally get the real ones.

[xjtrailrider]

The Longfields were shipped yesterday, just waiting on the big brown Santa to arrive:wings:

I have my winch mostly back together, the gear case is done and my motor is back from the rebuild shop. I just have to bolt the motor on and try it out.

I need a couple of things for it though;

A hook, I can't fond one locally that will handle 8k

The hardware to attach the hook to the 5/16 cable, I can't afford synthetic line yet and my cable is good.

I need a "WARN" sticker that will fit the motor can so folks will know its a WARN! It looks nothing like a WARN winch.

Pics soon to come of the shafts and the winch.

Anyway, I will be building a bumper soon since I have plenty of time on my hands, I only work 8 days this month. Stupid lay-off.

[Scrambled]

Jon give me a call I'm thinking about upgrading to synthetic cable on Lucky.


Also have a few side jobs I'm not gonna be able to get to you might be interested in.

Later
Sean

[xjtrailrider]

Jon give me a call I'm thinking about upgrading to synthetic cable on Lucky.


Also have a few side jobs I'm not gonna be able to get to you might be interested in.

Later
Sean

Thanks Sean, will do!

[hadfield4wd]

The Longfields were shipped yesterday, just waiting on the big brown Santa to arrive:wings:

I have my winch mostly back together, the gear case is done and my motor is back from the rebuild shop. I just have to bolt the motor on and try it out.

I need a couple of things for it though;

A hook, I can't fond one locally that will handle 8k

The hardware to attach the hook to the 5/16 cable, I can't afford synthetic line yet and my cable is good.

I need a "WARN" sticker that will fit the motor can so folks will know its a WARN! It looks nothing like a WARN winch.

Pics soon to come of the shafts and the winch.

Anyway, I will be building a bumper soon since I have plenty of time on my hands, I only work 8 days this month. Stupid lay-off.

Who cares if other people know its a warn.

For the hook call a rigigng company. Get the one with the locking mechanism.

[xjtrailrider]

Who cares if other people know its a warn.

For the hook call a rigigng company. Get the one with the locking mechanism.

I'm just OCD is all, I like things done right and detailed.

[Scrambled]

Your not OCD Jon . . . your CDO ,all the letters are in perfect alphabetical order just as they should be.:D

Later
Sean

[xjtrailrider]

Here are pics of the winch. I replaced all of the bearings, cleaned and glass shot blasted the aluminum, then clear coated the aluminum. I re-lined the brake band and replaced the main shaft plastic bushings with oil-lite brass ones. I added a drain plug to make oil changes easier( yes it takes oil! 1 quart of 30wt)

http://i418.photobucket.com/albums/pp266/xjtrailrider/potts/winch/P1010858.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/potts/winch/P1010859.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/potts/winch/P1010860.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/potts/winch/P1010864.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/potts/winch/P1010867.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/potts/winch/P1010862.jpg

[xjtrailrider]

I ran the winch today and it works awesome, that was without cable or load on it though. That thing turns real fast, reminds me of the 8274 that I had.

[xjtrailrider]

Bobby Long called me again today. It turns out that the axle shaft issue is a big misunderstanding. I'm getting the very first revised run of the shafts for a D-30. There are only 2 other sets out there and they are prototypes. I thought that they were manufacturing these shafts already, Bobby thought I knew they were still developing the shafts.

Any way, he has the shafts done and will ship them tomorrow.

[cootees]

Wow thats a clean old winch. I bet it took some time to clean that sucker up.

[xjtrailrider]

Wow thats a clean old winch. I bet it took some time to clean that sucker up.

Thanks, it wasn't too bad, I have about 3 hours in the rebuild and $30 in parts over the $150 I spent on it. Not bad for a 8000# winch.

[FitchVA]

Bobby Long called me again today. It turns out that the axle shaft issue is a big misunderstanding. I'm getting the very first revised run of the shafts for a D-30. There are only 2 other sets out there and they are prototypes. I thought that they were manufacturing these shafts already, Bobby thought I knew they were still developing the shafts.

Any way, he has the shafts done and will ship them tomorrow.

we need to start a pool. i'm betting they still won't ship tomorrow.


;) hopefully this will mess with it's "mojo" and they'll actually ship them out this time and not "mis-communicate" with you this time.

[xjtrailrider]

we need to start a pool. i'm betting they still won't ship tomorrow.


;) hopefully this will mess with it's "mojo" and they'll actually ship them out this time and not "mis-communicate" with you this time.


You win! Bobby didn't call me today so he has not got them ready yet. I am getting a "healthy" discount due to the mis-understanding.:wings:


They have been making the 30 spline Rubi 44 shafts for a while but the 27 spline D-30 shafts are newly developed.

[xjtrailrider]

I got the call from Bobby today, the shafts have finally shipped!:wings:

Just waiting on the big brown Santa to roll up the street now!

[FitchVA]

I got the call from Bobby today, the shafts have finally shipped!:wings:

Just waiting on the big brown Santa to roll up the street now!

i'll believe it when they show up at your door :D

[hadfield4wd]

Did he provied a tracking number this time?

[xjtrailrider]

Nope but i trust Bobby's word since i got it from him this time.

[TrailReadyMJ]

Nice Jon, that winch almost looks new!

I think I may have a warn sticker lying around for ya :D

[xjtrailrider]

Nice Jon, that winch almost looks new!

I think I may have a warn sticker lying around for ya :D

Thanks Drew! Just let me know and either I will pick it up or I will get my son to stop by your work and pick it up.

[TrailReadyMJ]

Thanks Drew! Just let me know and either I will pick it up or I will get my son to stop by your work and pick it up.

Found it! I have it at work whenever you want to stop by. I am off Tues and Sun this week, and Mon, Sat, and Sun next week.

[xjtrailrider]

Found it! I have it at work whenever you want to stop by. I am off Tues and Sun this week, and Mon, Sat, and Sun next week.

Thanks Drew, I may stop by over the weekend or get Wade to come by.

[FitchVA]

Nope but i trust Bobby's word since i got it from him this time.

show up yet?

[xjtrailrider]

show up yet?

Yes they came in yesterday afternoon, I'm just now getting in from my 2nd job. I'll post pics when i get up today, I'm off until sometime next week from my full time/part time job.

[xjtrailrider]

Ok, here are the promised pics of the long awaited "Longfields"

http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010868.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010869.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010871.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010872.jpg

Cool sticker!
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010874.jpg

Yes they are pricey but the advantages easily out wiegh the cost.

Advantages;
Stronger, pure and simple, and at full turn lock you loose none of the strength like you do on U-joint style shafts

If they do break(which they won't) they have a lifetime replacement warranty and they will not "pop" the knuckle when they go like U-joint shafts do.

I can carry about a 100# less spare parts:D I no longer need spare shafts/knuckles/uni-bearings. If a shaft breaks(which it won't) I can just remove the broken shaft and stuff a rag in the axle tube and drive home:2thumbsup:

Dis-advantages;

I can't think of any, ask me in a few years! But you do have to modify the knuckles slightly to clear the dust boots.

Now to get started building those axle housings to stuff these things into. I have 4.88 gears, (Yukon front and Nitro rear), front/rear Aussie lockers, RuffStuff axle trusses, Yukon alloy rear shafts and some other "home fab" stuff to set up on my D-30/8.25 combo over the next few weeks.

Out with the 4.10's and in with 4.88's:wings:

[FitchVA]

bling bling! nice!!!!!!1one

i wish they would work with the warn hub kit. if they did, i'd get a set

[hadfield4wd]

Those are a thing of beauty.

[TrailReadyMJ]

Mmmmmmm..... purdy!!! :2thumbsup:

[cootees]

Nice. I still think its a bit odd that the next new thing for jeeps is going to be longfields. :)

[xjtrailrider]

Nice. I still think its a bit odd that the next new thing for jeeps is going to be longfields. :)

Well Birfs are a good design, Bobby just makes them better/stronger. Much better idea in theory than U-joints.

[xjtrailrider]

I started the install of the Longfields today. Pics to come!

[xjtrailrider]

I started the install of the Longfields today. Pics to come!

Ok, so I hit a snafu on the shaft install today. Just as I was getting ready to install the shafts Bobby called and said there was a issue with my shafts. The inner splines were cut the same as the hub splines. He found the issue on the 3rd set of shafts they cut. They are the same spline count but a different pitch. I am going to "overnight" my shafts to him on his UPS account and he will re-cut the splines and get the shafts back to me by the end of the week (hopefully).

I thought it was great customer service to let me know this and to take care of the issue on his dime.:2thumbsup:

So I should have it rolling again this weekend or early next week.

I'll keep you all posted:D

[xjtrailrider]

I just got off of the phone with Bobby and he is re-cutting my splines now and will ship them back overnight-UPS and I should have them tomorrow evening. The shafts left Salem last night for Washington state. Thats good customer service:D

[xjtrailrider]

UPS failed me so it will be Monday before it rolls again. I thought I would start my write up on the shaft install anyway.


First, the Longfields have a dust boot that covers it to keep mud and crap out. Because of this boot the knuckles need to be modified. I had 2 sets of spare knuckles so i modded both sets at one time.

This is done by grinding out the bosses where the uni-bearing bolts go through with a 4-1/2" grinder. Longfield supplies a depth gauge to check your work and make sure you grind enough metal out.

http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010878.jpg

The depth gauge should fit flush with the bosses.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010881.jpg

And centered.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010880.jpg

The finished product;
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010879.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010883.jpg

Here is the boot that has to fit in there.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010882.jpg

Removing the old knuckles;

Loosen the ball joints but leave the lower nut on them. Also remove the tie rod end.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010886.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010885.jpg

I use the 2 hammer method for poping the knuckles, One small ballpen against the knuckle and one big Mo-Fo hammer to wack against the flat of the smaller hammer with.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010888.jpg

It usually takes 5 solid whacks.

The new knuckles are installed along with the tube seals (Thanks Fitch) and I'm just waiting on the shafts now.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010889.jpg

[xjmudman96]

LOokIn good jon. So those news seals will keep debree from getting down the outer housing part of the shaft too huh. do you still leave the internal seals in? Or have you already yanked them?

[hadfield4wd]

LOokIn good jon. So those news seals will keep debree from getting down the outer housing part of the shaft too huh. do you still leave the internal seals in? Or have you already yanked them?

These are an extra, not a replacement. I'm about 99% sure he has the internal seals as well.

Jon,


Are you done yet?:harhar:

[FitchVA]

LOokIn good jon. So those news seals will keep debree from getting down the outer housing part of the shaft too huh. do you still leave the internal seals in? Or have you already yanked them?

you leave the OEM seals in. these aren't meant to hold any fluid in. rather, they are for keeping mud and muck out of the axle tubes.

[xjtrailrider]

These are an extra, not a replacement. I'm about 99% sure he has the internal seals as well.

Jon,


Are you done yet?:harhar:

Correct! My inners are new. The Longfields do not have the plastic slinger that keeps gunk out of the tubes so thats all I really need the outers for.

I got my shafts back from Bobby today so they will get installed tonight or tomorrow.

[xjtrailrider]

OK, the Longfields are in and work great, no issues at all.

I got the shafts back yesterday and after popping them back into the birfs I installed them into the knuckles and pressed on the boots.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010891.jpg

Bobby gives you a tool to help with this but I found the 30mm wrench was a little better to get the boot started with then i finished with the install tool.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010892.jpg

So after the shafts, dust shields and uni-bearings were installed I tightened the bearings up with the included bolts, they have a beveled head to clear the boots.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010894.jpg

Then after everything was torqued to spec I turned the steering to each lock to check for clearance issues. Check out the neat little grease fitting that Bobby puts in there and he also supplies the needle to put the grease in with.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010895.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010896.jpg


So here they are, install was simple and everything fit great.
http://i418.photobucket.com/albums/pp266/xjtrailrider/longfields/P1010897.jpg

[hadfield4wd]

Almost makes me want to swap in a D30.:2thumbsup:

[FitchVA]

your colors clash :p

[RUparrothead]

your colors clash :p

Are those orange on a blue jeep? Seems kinda UVA-ish to me.:sSc_eek2:

[hadfield4wd]

Jon,

I just saw this thread on Pirate. Good winch motor swap on you winch.

http://www.pirate4x4.com/forum/showthread.php?t=382401

[xjtrailrider]

Jon,

I just saw this thread on Pirate. Good winch motor swap on you winch.

http://www.pirate4x4.com/forum/showthread.php?t=382401

Yep, I read that one a while back, he uses the Superwinch armature in the Warn motor can and does away with the sprag on the end of the motor. Its pretty slick! That gives you a fully functional reverse-out.

That thread was originally posted on IH8MUD.com or Alaskaoffroaders, one or the other.

[xjtrailrider]

After spending the first half of the year collecting parts for new axles I finally got started on the build up last week. I started with the rear, its a 8.25 and will be geared with NITRO 4.88's, Aussie locked, YUKON alloy shafts, RuffStuff trussed and RuffStuff cover.

I spent Friday setting up the gears, I have the pinion depth set which was made ultra easy by my homemade pinion depth gauge. At the last minute I decided to not use a crush sleeve and go with a spacer so that trail repairs would be simple and the pinion pre-load would not be compromised. I found a spacer/shim set made for the 8.25 from a company called RATECH (http://ratech.stores.yahoo.net/), I'm waiting for that to come in right now to reassemble the gears and be done with the set-up.

Here is my set-up so far;
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020141.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020143.jpg

I was going to drill my yokes out to use the u-straps but found some titanium straps that are said to hold up even better and not crush the caps like the u-bolt do. Here is a pic;

http://gallery.lisaandmike.org/albums/forsale/PICT2953.jpg

I'm also waiting on my LUBE LOCKERS, RuffStuff covers and the u-joint caps then I will have all of my parts. They all should be in this week.

More to come!

[FitchVA]

looking good! i wish i had 4.88's or better. are you going to stick with the drums or go disks?

[rubican!]

awesome i need to throw down some 4.88's as well. Looking good.

[xjtrailrider]

looking good! i wish i had 4.88's or better. are you going to stick with the drums or go disks?


Drums for now, I may do discs on both XJ's next year. It stops great on the drums though, I just want discs to hold the axle in just in case of snappage.

[xjmudman96]

very nice work. :thumb: Is it the first 3 numbers on the diff cover that stands for the gear ratio? Mine is 408 up front. Does that sound right?

[hadfield4wd]

very nice work. :thumb: Is it the first 3 numbers on the diff cover that stands for the gear ratio? Mine is 408 up front. Does that sound right?

No.


Jon looks real good as usual.

[xjtrailrider]

very nice work. :thumb: Is it the first 3 numbers on the diff cover that stands for the gear ratio? Mine is 408 up front. Does that sound right?

Nope! Kevin if you have a 4.0/AW4 XJ you are geared 3.55 unless someone has re-geared both axles. If you have a 4.0/AX15 then you have a 3.07 ratio. The 4-bangers can have many different ratios from 3.73 to 4.56 from the factory.

[xjtrailrider]

I ordered my RuffStuff covers Saturday morning and they arrived today! Dang, Dan is fast!

[FitchVA]

lucky you! every time i've ordered from him (2 diff guards at different times, 8.8 simple swap kit, and frame stiffeners) it's taken forever. that being said, dan was always in touch and usually shot me a message shortly after i ordered to tell me how they were out of stock. just bad luck on my part.

[xjtrailrider]

lucky you! every time i've ordered from him (2 diff guards at different times, 8.8 simple swap kit, and frame stiffeners) it's taken forever. that being said, dan was always in touch and usually shot me a message shortly after i ordered to tell me how they were out of stock. just bad luck on my part.


Well when i ordered them Saturday i really never expected them to ship until today but when i got home Saturday evening he had already sent me a e-mail saying they were shipped! He sent them in a flat rate box, talk about 35# of chit in a 10# bag:rotflmao5:

[FitchVA]

lol, yeah, he likes shipping them in those flat rate usps boxes. my mailman cussted me when each of my orders (minus the frame stiffeners) were ordered.

[xjtrailrider]

The rear axle is complete...almost. I still have to make skid plates for the shock mounts, fab up some brake lines and paint it.

I decided to go with a spacer instead of a crush sleeve, crush sleeves are fine for most but I like trail repairs to be simple and as close to permanent as possible. Since it is impossible to properly reset the pinion pre-load to spec without replacing the crush sleeve every time I installed a spacer from Ratech.

Here they are;
On the left is the spacer/shims and on the right is the crush sleeve.
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020145.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020146.jpg

So after the gears were installed and set to spec I went to work on the truss and shock mounts. I took the axle to work to do the welding and found that they had replaced my favorite welder (GRRRR), a Miller 251, with a Miller 450 with separate feed unit. I had issues getting a good bead and the stupid welder was both too powerful and had a auto-amp adjuster on it that kept messing with me so my welds look like crap! I tied the RuffStuff cover into the truss to spread any load that the housing may receive and to reduce ring gear deflection. I also installed the shock mounts as well.

Some pics:
Don't laugh too loud at the fugly welds!

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020148.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020149.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020150.jpg

Now I'm ready to start on the front axle:D

[cootees]

Jon, it looks good. Did you just gusset the housing, or are your intentions elsewhere. Sorry, I have not followed the build too closely.

[xjtrailrider]

Jon, it looks good. Did you just gusset the housing, or are your intentions elsewhere. Sorry, I have not followed the build too closely.

I added the gussets along with the bracket to the diff cover to tie into the truss. I might gusset the truss to help spread the load out a little further, not sure yet. I'm also going to add the traction bar mounts for that future upgrade as well. I'm still waffling back and forth as to whether or not I want to make a yoke guard.

[jhowery]

run more tubing close to the end of the axle tube. They could still bend with the truss point so close to the diff...

[xjtrailrider]

run more tubing close to the end of the axle tube. They could still bend with the truss point so close to the diff...

I was a little disappointed that when I got the truss from RuffStuff that it didn't extend out further but this is the truss that Dan recommended for the 8.25. I can extend it with no problems. The truss is 2-piece and the inside section of it is 3/8" steel, the outer is 1/4". The truss alone weighs close to 30#s. I'm still playing with it so i might do some more work before the paint goes on. Here is a link to the trusses that Dan makes;

http://www.ruffstuffspecialties.com/catalog/axle-trusses-c-8.html?osCsid=ecd9d1f9e7160a2b51490c78d760e0e9

[xjtrailrider]

Well I bit the bullet today and ordered the MIG conversion for my Wire Feed Hobart. I should have prettier welds now and I don't have to carry stuff to work to weld.

[Scrambled]

Well I bit the bullet today and ordered the MIG conversion for my Wire Feed Hobart. I should have prettier welds now and I don't have to carry stuff to work to weld.

Yeah I know the feeling Jon it gets old after a while staying late!

Miller 251 by far my favorite welder I have ever used! Have one at work as well and I love that thing!

Excellent work and write up as always my friend.:2thumbsup:

Later
Sean

[Sawace]

Well as far as I know it goes 2 the last page uve viewed or something unless u press last page but maybe one of the other mods can help u a little bit more. Im not completely sure about this

[xjtrailrider]

HuH!^^^

Anyway, I did a little more work on my rear axle this weekend and hope to completely finish it this week.

I'm catching a lot of crap on NAXJA for the height of the truss and the fact that the truss does not extend out further to the spring perches. I agree it looks hideous but it will be functional.

I did add some gussets to spread the load some. I also added shock mount skids and I'm making my traction bar mount and will add that today. I think I am going to have to put the traction bar on the drivers side and build a cross member to mount the frame end to. there are too many things in the way on the pass side.

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020156.jpg

[hadfield4wd]

I'm catching a lot of crap on NAXJA...


You know what I think about that.:rolleyes-1:


I think I am going to have to put the traction bar on the drivers side and build a cross member to mount the frame end to. there are too many things in the way on the pass side.


It can be done. All you need is a smaller muffler. Phil got me mine. Just come over a take a look at mine again. It's not as difficult as people say.

[xjtrailrider]

The rear axle is done, sorry no pics.

My newest addition to the rig, a WARN XD9000i that I traded Howery for. I had to make some repairs to it but so far I have no money in. Thanks to Josh for giving me a good deal on this winch, I know that it had been much less than dependable for him but I threw my lucky horseshoe into it when I put it back together so we will see:D

http://i418.photobucket.com/albums/pp266/xjtrailrider/hobbies/winch2.jpg

My next projects are;

1) the front axle, set-up the 4.88's, Aussie Locker, Longfield Shafts, and truss/skid plate it.

2) winch bumper for my new toy

3) my new T-case with AA HD SYE, Tera-2 low and Novak shifter

[xjtrailrider]

The front axle project is at a stand still untill football season is over for my Peewee team (2 more weeks) so I have been researching front bumpers and I think I will be ordering this one soon from LMP unless someone knows of a better deal. This one is around 400+shipping. I like the way it is built. Here is a link to their site (http://www.logansmetals4x4.com/id9.html)

http://www.logansmetals4x4.com/sitebuildercontent/sitebuilderpictures/.pond/JoshRafter.jpg.w560h328.jpg

[FitchVA]

i def like the lines of that bumper. that's in my folder of "cool" bumpers that i'm gonna try and emulate when i build mine :2thumbsup:

[xjtrailrider]

i def like the lines of that bumper. that's in my folder of "cool" bumpers that i'm gonna try and emulate when i build mine :2thumbsup:

I would love to build one and I have the Detours Backbone to work from but I have too many other things going on right now. I was given free access to all of the steel I would need and the Miller 452 at work to weld it with but I have little time to do anything right now. I might keep the Detours for a future bumper project.

[Scrambled]

I like the fit of that one Jon. How far does it extend from the grill?

Later
Sean

[xjtrailrider]

I like the fit of that one Jon. How far does it extend from the grill?

Later
Sean

Just enough but not too much

http://www.logansmetals4x4.com/sitebuildercontent/sitebuilderpictures/.pond/XJBumperSB2.jpg.w300h225.jpg

[hadfield4wd]

You lose departure angle. Do it once, do it right. Use your detours backbone and cut into the grill to set it as far back as possible. I wish I had done that with mine.

[FitchVA]

yup yup, my current plan is to sink that puppy right into the front of the jeep. ...it's easier to say than do though. ;)

[xjtrailrider]

You lose departure angle. Do it once, do it right. Use your detours backbone and cut into the grill to set it as far back as possible. I wish I had done that with mine.

I agree but really the angle is not too bad on that bumper, the angle stays consistent with the engine skid, see pic below. As far as making my own, yep, I could do it with no problem but I have other projects on the table right now.

Build and truss front axle
Homebuilt Thor Guards
Install axles in 2 XJ's
Build T-case for Old Blue
Build roof sliders like the HD Offroad version
Late model MC/Booster and steering box in the black Jeep, the list goes on and on.

http://www.logansmetals4x4.com/sitebuildercontent/sitebuilderpictures/.pond/FoslerXJBP.jpg.w300h225.jpg

I'm going to make some roof sliders similar to these but out of round bar and they will look better I hope.


http://i61.photobucket.com/albums/h76/bfourman/HD%20Roof%20Sliders/DSCN0382.jpg

[hadfield4wd]

You have swapped more axles in jeeps than I care to count. I'd still build one.

[hadfield4wd]

yup yup, my current plan is to sink that puppy right into the front of the jeep. ...it's easier to say than do though. ;)

True, it's easier to tell you how to do than actually do it.:thumb:

[xjtrailrider]

I talked to Mark at Detours about taking my Backbone and making a winch mount out of it. He did not recommend it on mine since the unit I have was built for recovery only and it was never intended to have a winch mounted to it. He said he could build me a new Backbone for $265. I have no doubt that his new Backbone would be more than sufficient but I still would not have a complete bumper. I can get the "basic"(without brush guard) LMP for $299 and it is rated for 10K. If I did make a bumper out of my Detours it would just be a bumper.

I guess thats why I am thinking of a purchase rather than build one right now.

[xjtrailrider]

Well I got the OK from the "other half" to order my bumper. Now I have to decide whether or not I want it with the brush guard or without. As you all know, I run my antenna on the front and would still have to make a mount for that to raise it above the hood, the brush guard would give me a mounting point for that.

I REALLY hate to not go with a Detours product here but I want a full bumper and just can't see spending 280 for a winch mount and then still have to build a bumper around it. My old Detours Backbone will be for sale.

With brush guard;
http://www.logansmetals4x4.com/sitebuildercontent/sitebuilderpictures/.pond/XJBrushandPowder.JPG.w180h70.jpg

Without brush guard;
http://www.logansmetals4x4.com/sitebuildercontent/sitebuilderpictures/.pond/XJPowder.jpg.w180h95.jpg

[hadfield4wd]

Thats a sharp looking bumper. I'd get the guard.

[RUparrothead]

My vote is to get the guard also.

[xjtrailrider]

I'm getting the one with the guard. I'll order it tomorrow and let you know how it fits when I get it. Now my next question is would a aluminum hawse fairlead be sufficient? I hate those big bulky roller fairleads like I had on my 8274.

[xjtrailrider]

I won't get the bumper until next week. Jamie at LMP e-mailed me on Sunday and said she is shut down all week with the H1N1 flu, everyone in her shop has it:(.

The good news is my bumper is built and sitting on a pallet. It just needs to be shipped and she said if she felt better later this week she would get it out. She has 11 bumpers that are going out with mine so I'm not alone in my misery:D

[RUparrothead]

I won't get the bumper until next week. Jamie at LMP e-mailed me on Sunday and said she is shut down all week with the H1N1 flu, everyone in her shop has it:(.

The good news is my bumper is built and sitting on a pallet. It just needs to be shipped and she said if she felt better later this week she would get it out. She has 11 bumpers that are going out with mine so I'm not alone in my misery:D

Make sure you douse it with lysol before handling it too much.

[hadfield4wd]

Make sure you douse it with lysol before handling it too much.

Nope gasoline and light it. Make sure you get video.:thumb:

[rubican!]

x2 on gas and match:thumb:

[xjtrailrider]

Wont matter, H1N1 is all around us. Its just like any other virus, you either will get it or you won't. The trick is keeping your hands clean and your fingers out of your nose, mouth and eyes.

[hadfield4wd]

your fingers out of your nose,

Crap I'm screwed then.:sSc_eek2:

[xjtrailrider]

I finished the set-up on the front gears. For some reason I had a lot of trouble getting this pattern just right even with my set-up bearings and then when I pressed on the new new bearings it all went to heck again. So I have been into the pinion depth and BL about 2 dozen times on this gear set and here is where I'm going to settle at. The coast side looks good but the drive side looks like the pinion is not deep enough but even a .005 shim sends it too far the other way. Very aggravating.

Crappy cell phone pics:D

Drive side
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/gears.jpg

Coast side
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/gears2.jpg

[xjtrailrider]

Here is the rear, I'm good with the 8.25. It has to be the easiest axle to set. I went with a pinion spacer and shims on this one instead of the crush sleeve. The spacer/shims make it much easier to do trail repairs such as changing a broken yoke or replacing a seal.

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020143.jpg

Crush sleeve on the right, spacer/shims on the left.

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020146.jpg

[Scrambled]

Digging the build as usual. Guess I still miss my old XJ a lil huh? LOL

Ive had a few R&P sets that I had to fight for a while to my friend.

Are you using a pinion depth set gauge? I got mine from Jegs or Summit years ago for less than a $100 bucks. Cant remember which I got it from sorry been a while.

Did you ever pick up an " # torque wrench for yourself?

Later
Sean

[xjtrailrider]

Digging the build as usual. Guess I still miss my old XJ a lil huh? LOL

Ive had a few R&P sets that I had to fight for a while to my friend.

Are you using a pinion depth set gauge? I got mine from Jegs or Summit years ago for less than a $100 bucks. Cant remember which I got it from sorry been a while.

Did you ever pick up an " # torque wrench for yourself?

Later
Sean

Yep, I'm using a homemade depth guage but for some reason this R&P wasn't marked on the pinion. I found a "2.261" marked on the ring gear and went with that but it was too far out, so it was trial and error from there. I picked up a beam style inch pound torque wrench made by Armstrong for $40 on the net and it is making pre-load a easy deal.

Sean, Do you think that pattern is going to give me trouble or is it acceptable?

[xjtrailrider]

My bumper is on its way :wings: Got a e-mail from LMP and a tracking number.

[TrailReadyMJ]

That pattern looks perfectly acceptable to me Jon, I'd run it :thumb:

8.25 are pretty easy aren't they, about the only axle that's easier to work on would be a 9". The last 9" I did only took me about 3-4 hrs including teardown and converting from 28 to 31 spline :) .

[xjtrailrider]

That pattern looks perfectly acceptable to me Jon, I'd run it :thumb:

8.25 are pretty easy aren't they, about the only axle that's easier to work on would be a 9". The last 9" I did only took me about 3-4 hrs including teardown and converting from 28 to 31 spline :) .

Thanks Drew! Yep I'm going to run it just like that. That particular Yukon D-30 gear set was a hand full to get right for some reason.

Where are you all wheelin now?

[TrailReadyMJ]

Where are you all wheelin now?
Well, really haven't been... need more time!
They went to URE last month, but that's about it. Unfortunately I couldn't make it, too many projects.

[xjtrailrider]

Well, really haven't been... need more time!
They went to URE last month, but that's about it. Unfortunately I couldn't make it, too many projects.

I have had the same problem, cant seem to find more than an hour here and there for anything. I will be giving you a call soon, my son needs a remote start on his 96 XJ as soon as he gets the money together.

[xjtrailrider]

Well, tonight when I opened my front door to give out candy to the little trick or treaters I found a notice on my front door from FedEx. They tried to deliver my front bumper yesterday but I was at the Dr's office getting blood work done (having some health issues) anyway, i missed the shipment of my bumper so I guess I will have to call them Monday am and schedule a drop off time. Aaarrrgh!

[xjtrailrider]

The bumper is here, so If all goes well I will have it mounted by Friday.

[xjtrailrider]

I finally got my winch and bumper mounted.

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020170.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020171.jpg

[hadfield4wd]

Jon that's really nice. I like it the desert tan.

[xjtrailrider]

Jon that's really nice. I like it the desert tan.

Thanks, I wanted something different, there are way too many black winch bumpers out there.

I knew I had done a good job when Angie told me it looked like a redneck piece of chit:2thumbsup:

[TrailReadyMJ]

Looks great Jon! :2thumbsup:

[hadfield4wd]

That antenea has got to go.

And you can tell I Angie I said she just doesn't have good taste.

[spikes jk]

real nice:2thumbsup:

[RUparrothead]

As already said, looks amazing. However, Matt is right...the antenna up front has to go.

[drakan1908]

Looks great! :thumb:

[xjtrailrider]

Thanks all!

I have the antenna there for 2 reasons; 1) I get great SWR's there (.7) with the hood for a ground plane. 2) it will lay flat on the hood while going through low trees or if I flop it, it shouldn't ever break there.

I agree its ugly but I'm a "function over form" guy, looks are always a second thought.

[FitchVA]

bumper looks sweet :2thumbsup:

[RUparrothead]

I agree its ugly but I'm a "function over form" guy, looks are always a second thought.

Good point.

[hadfield4wd]

Serously Jon, are you trying to contact the home planet or something?:harhar:

My CB only works half the time and I have to give it a good wack at that.

[FitchVA]

Thanks all!

I have the antenna there for 2 reasons; 1) I get great SWR's there (.7) with the hood for a ground plane. 2) it will lay flat on the hood while going through low trees or if I flop it, it shouldn't ever break there.

I agree its ugly but I'm a "function over form" guy, looks are always a second thought.

blah! just admit that you are too lazy to rerun the wires :harhar:

[xjtrailrider]

Serously Jon, are you trying to contact the home planet or something?:harhar:

My CB only works half the time and I have to give it a good wack at that.

No, only the mother ship:D the trail rig radio is only putting out 70 watts.

Right now the antenna is not hooked up, I have to pick up a new Amphenol connector Friday.

[xjtrailrider]

The front axle is getting close to being done. The axle is complete right now with some spare shafts stuck in there for the welding. The truss is cut and fitted just waiting on me to melt some metal. The truss is made of 2"x4"x1/4" box with the bottom cut out.

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020179.jpg

[hadfield4wd]

I forgot to ask the other day. Are you doing something on the driver side of the pumkin? Also as you drilling holes in the truss? It won't effect the stregth. Also dont weld it fully. 2 inch stitch welds, 2 inches apart. Start at the corners and work your way to the middle.

[xjtrailrider]

Not sure yet Matt, there is not a lot of room in there so i don't know if it would be that beneficial. If I had stripped all of the bracketry off the housing and started over that would have been a better idea. I'm leaving it solid, I could cut some holes in it and weld in some pipe for a cool feature. My plans are 2"stitch welds spaced equally.

[RUparrothead]

I have to ask...what is the purpose of "trussing" an axle? Is it mainly for support of the housing, or is there something else I'm missing?

[hadfield4wd]

I have to ask...what is the purpose of "trussing" an axle? Is it mainly for support of the housing, or is there something else I'm missing?


Yeah strength.

[RUparrothead]

Thought so. Thanks.

[xjtrailrider]

I have to ask...what is the purpose of "trussing" an axle? Is it mainly for support of the housing, or is there something else I'm missing?

To minimize flexing/bending of the axle tube and differential during off road maneuvers.

[hadfield4wd]

To minimize flexing/bending of the axle tube and differential during off road maneuvers.

aka strength:D

[xjtrailrider]

Ok Matt, here is an idea;

Say I build a short truss for the drivers side then bridge it over the pumpkin with some beefy 1/2" stock that I have and then not welding to the pumpkin itself. This would reduce any chance of warpage between the 2 metals (due to cooling rates)And should be plenty strong. I also would not have to worry about the welds cracking due to cooling rates either.

[xjtrailrider]

Almost done trussing the front axle. I also got the TeraFlex 2-low kit for Christmas and I have a new AA HD SYE and a new 231 T-case ready to be set-up and installed. I have a lot of work to get done this winter.:2thumbsup:

[hadfield4wd]

Jon you have been really busy. I guess vacation is good for something. I still think you should do the tera low while you're in the tcase.

[xjtrailrider]

Jon you have been really busy. I guess vacation is good for something. I still think you should do the tera low while you're in the tcase.


I would love to but I just don't have the money, gotta make those Commander payments now:D

[xjtrailrider]

WOOT!! I finally got the axles done:thumb:

Both front and rear are Aussie locked, the front has the Longfield shafts and the rear has Yukon shafts. I have 4.88's in both, Yukon's in the front, Nitro's in the back. The rear has a "massive" RuffStuff truss that is 1/2" steel(bottom plate) and 1/4" steel upper "C" channel. The front truss is "home fab chit" by me and is made from 2"x4"x1/4" square tubing.

All thats left is to plumb the rear axle for brakes and install the UCA bushings in the front axle.

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020209.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020210.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020217.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020222.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020216.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020223.jpg

I'll put them on a back burner until next weekend
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020224.jpg

[xjtrailrider]

On to my next project!

I have this NP231 just sitting around that has low miles on it. I have a SYE in my current T-case but I decided to build a fresher one. This one is getting the Advanced Adapters HD SYE and TerFlex 2-Low. I'll be keeping my old 231 for a spare.

I had to retrieve it from the Jeep barn today, I figured a sled was a better way to move it considering the conditions.

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/0207101344.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020226.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020227.jpg

[Big Red 95]

nice work on the trusses. they look almost to pretty to get dirty.

[xjtrailrider]

The T-case is done and ready to install. The 231J now has a TeraFlex 2-low kit and a Advanced Adapters HD SYE kit. This low mileage case will replace my aging 231J that has the Advance Adapters HD SYE kit already installed.

[jhowery]

The T-case is done and ready to install. The 231J now has a TeraFlex 2-low kit and a Advanced Adapters HD SYE kit. This low mileage case will replace my aging 231J that has the Advance Adapters HD SYE kit already installed.

2-low is awesome. :thumb: It is great for tight trails; one of my favorite mods on my old XJ.

Got the 5687 mounted and cable loaded on it Saturday. Just have to run the cable controls. :wings:

[xjtrailrider]

2-low is awesome. :thumb: It is great for tight trails; one of my favorite mods on my old XJ.

Got the 5687 mounted and cable loaded on it Saturday. Just have to run the cable controls. :wings:

Josh I can't wait to see the 5687 in action with the cable controls!

[xjtrailrider]

I finished up the T-case today and gave it a coat of paint. Its a low mileage 231 with a Advance Adapters HD SYE and a TeraFlex 2-low kit. I will be installing it next weekend hopefully.

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/t-case1.jpg

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/t-case2.jpg

[xjtrailrider]

I decided to eliminate the stock air box and go with a inline filter from Spectre. I constantly had issues with the air tube being smashed by the drivers side front tire. I ordered a Spectre 9833 4" inline filter with 3" inlet/outlet. Its rated at 450 CFM which is about a third more than the 4.0 needs at WOT and a 75% VE

I was able to remove about 3' of air tube from the snorkel and the entire air box assembly which will give me plenty of room for a dual battery set-up now. here are some pics of the filter kit and the install.

http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020248.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020249.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020252.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020254.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020255.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020256.jpg

What I removed;
http://i418.photobucket.com/albums/pp266/xjtrailrider/airbox/P1020257.jpg

[xjmudman96]

That's a really good set-up :thumb:

[hadfield4wd]

I like that.

Is that a K&N filter?

[xjtrailrider]

I like that.

Is that a K&N filter?

Nope, its a Spectre filter. Its possible that it could be made by K&N though, its very similar in construction.

[Big Red 95]

That is freakin sweet man. I bet that even works better too. looks like it is sealed tight.

[rubican!]

looking really good. I bet it changes the sound alittle bit to sounds meaner i bet.

[xjtrailrider]

Thanks everyone! i haven't driven it yet since I let the tags run out in January. I guess I should order some tags tomorrow so i can drive it around.

[xjtrailrider]

To follow up the new in-line air filter, it runs great and does sound different. Most importantly I can now flex with the left front without killing the air tube so it was worth the effort and price.

I finally got motivated today and swapped out the T-case. The old T-case had about 120k on it and is in great condition with a Advance Adapters SYE in and a rebuild at 90k but my new case has only 80k on it with a Advance Adapters SYE and TeraFlex 2-low kit that I recently installed.

Out with the old, in with the new.
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020269.jpg

I went a little slow on this T-case swap, it took about an hour and a half:D

[hadfield4wd]

I was wondering when you were going to do this. I was going to ask you, but I was in the Principal's office so I didn't.

[xjtrailrider]

I was wondering when you were going to do this. I was going to ask you, but I was in the Principal's office so I didn't.


Thats a familiar place for you:harhar:, I had yesterday off for a holiday (good Friday except we close on Thursday since we don't work Fridays). I got a bunch of work done and I plan on pulling the rear axle tomorrow. Right now I'm headed out to pull the hardtop off of the JK.:wings:

[hadfield4wd]

Thats a familiar place for you:harhar:,

If you only know how true that was. I had flashbacks yesterday.


Right now I'm headed out to pull the hardtop off of the JK.:wings:

Nice.

[xjtrailrider]

I had my own Easter Sunrise service in the garage this morning.
I swapped out the rear axle for the new one, took about an hour and then went in for breakfast with the family.

The old 8.25 with the Detroit
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020271.jpg

About a half hour later
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020272.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020273.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020274.jpg

My Yukon shafts that will go into the new axle
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020270.jpg

And finally the new axle bolted in. I still need to plumb the brakes and remove the stock shafts that I used for set-up and install the Yukons. Many nay-sayers on NAXJA said that my truss would hit the tank skid or the exhaust, note that even at ride height I have plenty of room for flex. My measurements were spot on.
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020276.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020275.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020277.jpg

[hadfield4wd]

I had my own Easter Sunrise service in the garage this morning.

Spiritual experience was it?:D


Many nay-sayers on NAXJA said that my truss would hit the tank skid or the exhaust, note that even at ride height I have plenty of room for flex. My measurements were spot on.

Say it ain't so? Nay-sayers on Naxja? What a shock.:rolleyes-1:

[xjtrailrider]

Spiritual experience was it?:D

Always:rotflmao5:




Say it ain't so? Nay-sayers on Naxja? What a shock.:rolleyes-1:

I got flamed by some on there for the height of the truss and true i could have cut it down some but oh-well. When I asked why the nay-sayers thought it was too tall they all said it would not work around the tank and exhaust. I didn't argue, i knew it would be ok.

[jhowery]

Always:rotflmao5:I got flamed by some on there for the height of the truss and true i could have cut it down some but oh-well. When I asked why the nay-sayers thought it was too tall they all said it would not work around the tank and exhaust.

ah, web wheelers...nothing makes up for hands on experience like spending all your time on chat forums...

:rolleyes-1:

[xjtrailrider]

^^LOL!

I got the rear axle finished up tonight and will test drive in the morning then start on the front. I hope to have it on all fours by Thursday evening.

[xjtrailrider]

4.88's rock:wings:

So does front and rear Aussie lockers banging, clanging and tires chirping both in front of you and behind you:D

[xjtrailrider]

The front axle is in, pics to come tomorrow.

[xjtrailrider]

The old front axle is out and the new one is in. It went smooth. Some pics of the front swap and of the finished product after a long road test. It runs nice, very quiet and its nice to get into OD/TC lockup at 35 mph:yup:

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020278.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020279.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020280.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020281.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/P1020282.jpg

[hadfield4wd]

That'll never work.:harhar:

Looks good.

Ok you sir are not officially out of excuses. Memorial Day weekend wheeling.

[xjtrailrider]

That'll never work.:harhar:

Looks good.

Ok you sir are not officially out of excuses. Memorial Day weekend wheeling.

I'm very creative, LOL!

[xjtrailrider]

A few driveway poser shots but with a purpose:D

I wanted to check out the truss clearances and bump-stop settings as well as shock extension/compression

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020293.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020292.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020290.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020289.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020287.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020286.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020285.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020284.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/P1020283.jpg

Everything looks good!

[Scrambled]

Jon that is one of the cleanest, well thought out, and streetable XJ's Ive seen. Good work as usual my friend.:2thumbsup:

[xjtrailrider]

Jon that is one of the cleanest, well thought out, and streetable XJ's Ive seen. Good work as usual my friend.:2thumbsup:

thanks Sean, it looks better in pictures though. I did loose a little bit of driving comfort when I put in the rear locker but it will be much better on the trail now. The old True Track wasn't cutting it anymore.

[hadfield4wd]

Jon,

I agree. What a nice job. Well thought out. I look forward to wheeling with you as you explore its capabilities. I think you'll be amazed. I wish I could make a potts run with you. I'd happily spot you up the ledge.

[xjtrailrider]

Jon,

I agree. What a nice job. Well thought out. I look forward to wheeling with you as you explore its capabilities. I think you'll be amazed. I wish I could make a potts run with you. I'd happily spot you up the ledge.

I'd happily decline a trip up the ledge:harhar: I need to break in the gears a little before i hammer on it.

[xjtrailrider]

I just got back in from breaking in my new gears. Went about 60 miles on 220 south at 55mph and they did good, no abnormal noises and that's on the cheap 70-80wt gear lube. I will drain out the diffs tomorrow and put the good stuff in, some Lucas 75-140 rear and 80-90 front.

I do have a slight rear DS vibe at 48-52mph but I suspect that is just from a slightly trail damaged DS that could use replacing some day.

[xjtrailrider]

Well its been a while since I updated my build thread and there is not much to report other than the axles are doing great:thumb:

I did have a issue with my winch not wanting to free spool so i took it apart and really can't find anything wrong with it but it is paying out a little easier now.

[xjtrailrider]

Long time since the last update! I'm installing the full case Detroit in the D-30 right now. Thats about as far as I can upgrade the D-30 to make it strong. Well see how it holds up.

[xjtrailrider]

I got the Detroit installed today, went well allthough I'm concerned I might have gotten the side shims a little tight. My set-up bearings went in easily but after I pressed on the new bearings, things got tight. I use TIMKEN for set-up and final set-up so I'm not sure where the difference is. I guess if I fry the carrier bearings I'll know I got them too tight:sSc_eek2:

You might ask; Why did you switch from the Aussie to the Detroit?

Well the Aussie is a "lunch box locker" and mounts into the stock carrier. The stock carrier in a D-30 is fine for 33"- tires but gets a bit anemic when twisting 35"s and lower gears.

Here is a pick to show the difference; Note, the Detroit is on the left, a stock(empty) 3.55- carrier is in the middle and a stock (loaded) 3.73+ carrier is on the right. note how much more meat the Detroit has, that bad boy should not break!

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/0114111603.jpg

Some have asked me: What is the difference in a 3.55- carrier and a 3.73+ carrier, or "carrier break"?

As you can see in the picture, the ring gear mounting surface is slightly more towards the center of the pinion on the 3.73+ carrier to allow for the smaller pinion gears

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/0114111604.jpg

So here is the final product, ready for some trail fun this year:2thumbsup:

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/0114111748.jpg

[xjtrailrider]

I haven't tried the Detroit out off-road yet but I like it better on road already, it is silent! None of the "bangin and clangin" that the Aussie made.

[xjtrailrider]

Old blue went on a diet and has exsersized 200lbs off its fat a$$ this winter! I put a Richard Simmons "Sweating to the oldies" tape in the deck and played it over and over until the fat melted off.

Pictures to follow when i get time but the tool box is gone and the gear is reduced to the bare minimum. I just couldn't let go of any tools, I figure that one tool I don't take will be the one I need on the trail.

I also got the power door locks to finally work. They tried to work but didn't. I started on the pass rear where I found that the actuator was hanging loose in the door LOL! So I reattached that and then pulled the door latch out and soaked it in WD40 over-night. I did this for the other 3 doors as well and I then cleaned them with brake cleaner and sprayed some white lithium greese into and all over the latches and re-installed them.

My door locks "snap" locked/unlocked for the first time since i have owned it.

[xjtrailrider]

Well its been a while since I have done anything to any of the Jeeps but Old Blue needed a new front R&P so;

I ordered a new set of Yukon 4.88's and had them drop shipped to Performance Cryogenics (http://www.performancecryogenics.com/) to be "cryoed". This will add about 20% more strength to the gear set. I pulled the D-30 out and set-up the new gears

http://i418.photobucket.com/albums/pp266/xjtrailrider/1217111225.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/1217111224.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/1223111410a.jpg

So with the gears set-up I decided to address some of the other issues with my front end. Hadfield had cut me a steering box re-enforcement plate a while back so I finished it up and installed it. I also have a MORE steering box brace to install

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/1223111409.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/1223112034.jpg

I also installed a new steering box while I was at it. Its now leaking worse than the other one was, hope its a "O" ring.

[xjtrailrider]

I also decided to make some bar pin eliminators out of a set of XJ rear sway bar mounts

http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/1222111419.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/axles/1222111419a.jpg

Then I addressed the track bar. My JKS track bar was only "single shear" so I fixed that and I'm making a frame brace as well to re-enforce it even more.

http://i418.photobucket.com/albums/pp266/xjtrailrider/1226111107.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/1226111338.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/1226111410.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/1226111411.jpg

My next mod is moving the tranny cooler to the top of the hood, stay tuned......

[xjtrailrider]

Also on my "to do" list is;

Rear quarter guards
Rear bumper
Roof sliders
Rear traction bar

[xjtrailrider]

I mounted the MORE steering box brace today;
http://i418.photobucket.com/albums/pp266/xjtrailrider/1230111202.jpg

My tranny cooler/fan combo came in today. I have to find a place to mount it and that aint easy on a XJ! Right now my cooler is in front of the radiator but when i added the winch I started having overheating issues so I'm moving the cooler to help out.

Here it is on the hood, that is the biggest possibility right now. I don't want to cut holes in the hood due to getting water into the ignition system and I want the cooler to be in fresh air if i can. I don't want it underneath due to the mud clogging it up on the trail.

http://i418.photobucket.com/albums/pp266/xjtrailrider/1230111408a.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/1230111408.jpg

[hadfield4wd]

Don't mount it on the hood. It looks very "unjonlike"

[xjtrailrider]

Don't mount it on the hood. It looks very "unjonlike"

Haha! yep but there just isn't any other options. I don't want it underneath=too muddy(plus the only place to mount it is where my traction bar is going). I don't want it under the hood or with holes drilled in the hood=too hot in there and I don't want water in the ignition system.

I thought about removing the left rear quarter glass, cutting plate to fit the opening then recessing the cooler into the plate. A lot of work for something I could just mount on the hood.

I just know I need to move it, My engine is running hot on the trails even with a new 3 core brass rad and all new coolant system. I started having issues when I installed the winch. It takes up too much grill space and the cooler is large as well and in front of the rad on the left side. Here is a pic of my current tranny cooler, you can see how much space it takes up.

http://i418.photobucket.com/albums/pp266/xjtrailrider/Old%20Blue/10.jpg

[hadfield4wd]

If you put it on the hood put a scoop or something to hide it. I don't get you guys and your cooling issues. The only time I have an issue is when something is broken. This is why I like my older closed system. Yes it requires more maintenance but if everything is up to snuff I dont have problems.

[xjtrailrider]

But you have a straight drive! If you had a auto it would be an issue.

[YJeXtreme]

What about upgrading your cooling fan setup on the radiator... Ditching the mechanical fan, for a better/more efficient electric setup, then mounting the new trans cooler/fan combo in similar location to your current cooler, so the rad fans are pulling, and the trans fan is facing so it's pushing towars the rad? Just an idea...
Even in my high horsepower bigblocks shoved into small body cars did I have an issue with cooling... and they were automatics too

[xjtrailrider]

What about upgrading your cooling fan setup on the radiator... Ditching the mechanical fan, for a better/more efficient electric setup, then mounting the new trans cooler/fan combo in similar location to your current cooler, so the rad fans are pulling, and the trans fan is facing so it's pushing towars the rad? Just an idea...
Even in my high horsepower bigblocks shoved into small body cars did I have an issue with cooling... and they were automatics too

The only improvement I could possibly make is to ditch the mechanical fan and add a e-fan to help the existing e-fan. The 3 core all brass rad is new but it has the condenser in front of that, then I added the tranny cooler and the winch. I have an air flow issue!

I have a plan on what to do. I'm going to give it a shot tomorrow, I'll post results if I get a chance to try it out.

[xjtrailrider]

I spent Saturday building a basket to protect the tranny cooler/fan combo. I was going to mount it on my hood but I need to look into the VASI laws as it does block some visibility.

Here are some finished pics

http://i418.photobucket.com/albums/pp266/xjtrailrider/0107121926.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/0107121719.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/0107121654.jpg

I might look into mounting it on the roof instead. I'm making roof sliders soon so I can mount it up there where it will be prtected from limbs. Here is what my roof sliders will look like;

http://i149.photobucket.com/albums/s44/xjjeepthing/Cherokee/IMG_0067.jpg

[hadfield4wd]

ugh

Jon don't do it. There had got to be a better way that isn't ugly. Not your fab work that is great as usual. Just the location.

[rubican!]

dont do it jon. I logged in just to say it!

[xjtrailrider]

Don't worry guys I'm not! I just hate that i have 5hrs and $25 in materials into the basket. Anybody need any expanded metal?

I have other plans, I'm going with dual e-fans pulling from the inside and a more efficient cooler than the one currently in there.

[xjtrailrider]

The tranny cooler is now moved over to the pass side. I got rid of the "zig-zag" style cooler and went with a much more efficient "stacked plate" style(the one that came with the fan/cooler combo). This turned out to be a 6 hour job since the winch had to be removed in order to get the grill out and put the new cooler in. As luck would have it when I was re-installing the upper radiator support I dropped a #8mm socket down into and behind the water pump pulley. Yep you guessed it, I had to take the pulley off to get to the stupid socket! Another hour wasted. While I was at it I installed a second B&M temp sensor in the output line of the tranny. Now I can toggle my tranny temp gauge between the output and input lines to see how efficient the cooler is working.

My original plan/reason for installing the cooler on the drivers side was that I was going to have a switch on my E-fan so that I could turn it on at low speed. The problem that I ran into with this idea is that when you disconnect the factory wire harness from the E-fan on a 96+ XJ(OBD2) it will throw an annoying CEL that has to be cleared each time. I got tired of dealing with that!

Now that the cooler is on the pass side it will get more air at low speed since the mechanical fan is always pulling the cooler will always be getting air even when crawling along at slow speeds. I plan on replacing the mechanical fan with a E-fan that will run off of a thermostat controller for even more air flow at low speed and less parasitic drag on the motor.

SO guys, no ugly fan/cooler/basket mounted on the hood!


The next project; Installing the rear disc brake set-up that I bought off of Fitch. It will be nice to be able to lock up the brakes if needed.

[YJeXtreme]

Glad you got it sorted out Jon, I'll be doing a similar upgrade in the near future to my XJ, the prev. owner hacked into the wires for the E-fan and ran to a switch, it's a bit redneck currently... but I can live with it for the moment

[xjtrailrider]

I started the ZJ disc brake conversion today.

First, removed both axle shafts and cleaned up the mounting surface

http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120121541.jpg

The ZJ caliper brackets have to have the center hole opened up since the 8.25 has a 3.25 diameter. I picked up these drum sanders from lowes and used my drill press to get the job done quick.

http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120121540.jpg
http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120122050.jpg

The mounting holes are also off center a bit, the easiest way to fix this is to just open all 4 holes up with a 27/64 drill bit

http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120122048.jpg

So then i mounted up all of the new parking brake hardware and then mounted the brakets to the axle

http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120122046a.jpg

I sorted out the E-brake cables next. Yhe problem here is that the cable ends on a ZJ are different than the ones on the XJ. I fixed this issue by drilling the lever to accept a 1/8 cable clamp but I only used the U part of the clamp. I also secured the cable to the bracket with hose clamps.

http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120122046.jpg

Since the rotors are thicker than the drums you have to run longer studs. I bought some 2" XJ front studs at Oriellys to fix that issue

http://i418.photobucket.com/albums/pp266/xjtrailrider/disc%20brakes/0120122053.jpg

As soon as I can source some banjo bolts then weld brakets to the axle tubes to mount the hoses to it will be done tomorrow.

Over all its been a easy job

[xjtrailrider]

Disc brakes are done, test drive tomorrow!

My next project will be a rear bumper and quarter guards. I already have the steel on hand for those and I'm placing the order for the steel for my roof sliders this week.

[xjtrailrider]

Test drive done. Better but still not what I was looking for. I can stop in reverse now, thats a plus. Something is rubbing, probably the rotor rubbing the dust shield.

[YJeXtreme]

Did you replace with the disc brake proportioning valve from the grand too? If not proper pressures for an all disc will not be acheived.

Good luck!

[xjtrailrider]

Did you replace with the disc brake proportioning valve from the grand too? If not proper pressures for an all disc will not be acheived.

Good luck!

Not yet, I need to source one