Project Coppertop Axle Swap

[Coppertop]

Picked up some axles yesterday.Even with the snow falling and the ground a snow/muddy mess ,I manage to cut the axles out.

http://i529.photobucket.com/albums/dd335/xjwheeling/Axleswap060.jpg

Dana 44 front and Dana 60 rear out of a 1979 F250. Paid 300.00 :)

Now ,let the adventure begin.....:evilgrin:

Nick

[KargoMaster]

nice... I bet you'll sure miss those 7 minute Dana30 axle changes, won't you?

[lky13blazer]

Great deal on the axles....hopefully by spring I'll be doing my yj.I'll be following this one for sure

[Hope Springs Hauler]

Is a disc brake swap on tap for the rear?

[Coppertop]

nice... I bet you'll sure miss those 7 minute Dana30 axle changes, won't you?

You know it..Changed out way to many...:D

Is a disc brake swap on tap for the rear?

For sure,Already been researching..Thinking bout these...
http://bluetorchfab.com/store/advanced_search_result.php?keywords=BTF11021&osCsid=k1gogtsu1pmhsu06la3trh42u0&x=10&y=11

The build sheet is in the works.

Nick

[boomhauer]

lky13blazer...if you are going to do the same to yours then i have a '79 ford rearend that you will want. $100.00 and it's yours. it is complete.

[lky13blazer]

lky13blazer...if you are going to do the same to yours then i have a '79 ford rearend that you will want. $100.00 and it's yours. it is complete.

thanks I'll keep it in mind but it will be at least after the first of the year before i get to...do you know the gear ratio? and bolt pattern?

[Coppertop]

The build list so far...

Clayton front axle bracket kit. http://claytonoffroad.com/product_info.php/cPath/18_71/products_id/83

6.5 Lift Rough Country Long Arm Suspension Kit
http://www.roughcountry.com/jeep_xj_6xla.html

Blue Torch Fabworks
http://www.bluetorchfab.com/store/
Dana 60 rear Disc Brake brackets ( BTF11021)
Rear Spring Perchs (BTF11016)
Rear Diff Cover/truss DYI Kit (BTF11076)
Front Diff Cover/truss DYI kIT(BTF11074)

Both front and rear trusses will be homebuilt.

Thinking about KM2 35's Tires and these beadlocks(Trailready)http://www.4x4groupbuy.com/store/trailready-beadlock-aluminum-wheels-16x10-8on65-p-8463.html

Gears will be 4.88's with a Front ARB locker and rear Detroit.

More to come...All comments welcome.

Heck ,I wanna do it right the first time.:D
Nick

[boomhauer]

thanks I'll keep it in mind but it will be at least after the first of the year before i get to...do you know the gear ratio? and bolt pattern?


8 lug, 3:54's

[KennyTJ]

If your gonna run beadlocks i'd get some serious offroad tires in a bias ply for strong sidewall. Something like a TSL. I run 36" TSL SX's and they are awesome with like 2psi in them. I would NOT run a radial tire sidewall in the rocks, you'll go from changing D30 axle shafts to replacing $200+ tire every trip. I run 35" BFG AT's on the street, great snow tire for on the highway also! with 6" lift you'll have plenty of room for a 36" and the axles are no problem.

Just my 2cents.

:D

[itbrokeagain]

I love the KM2s. Outrageously priced though. To get the size I want is around 3 grand for 4.

[Coppertop]

I like the TSL's too..But ,I need the best of both(Good street /trail tire).Still kicking around the bigger size tire(36).It's amazing how the price goes way up when you get larger than a 35..

Nick

[94Dodge Truggy]

If your gonna run beadlocks i'd get some serious offroad tires in a bias ply for strong sidewall. Something like a TSL. I run 36" TSL SX's and they are awesome with like 2psi in them. I would NOT run a radial tire sidewall in the rocks, you'll go from changing D30 axle shafts to replacing $200+ tire every trip. I run 35" BFG AT's on the street, great snow tire for on the highway also! with 6" lift you'll have plenty of room for a 36" and the axles are no problem.

Just my 2cents.

:D

I too have been amazed at how well the bfg at's perform. I owned 2 very similar trucks a few years back with 35" BFG at's and the other with bias ply 36" TSL's. Both new sets and in the light mud, deep snow and street the at's ruled. Deep mud and wet rocks were home to the TSL's though. Buy some maxxis trepadors! I am thinking of giving them a try.

[mckeddie]

my old 36'' iroks always amazed me how well they did on the street. they were bias, and unbalanced would run 80 mph down the highway smooth as silk.

[KennyTJ]

I too have been amazed at how well the bfg at's perform. I owned 2 very similar trucks a few years back with 35" BFG at's and the other with bias ply 36" TSL's. Both new sets and in the light mud, deep snow and street the at's ruled. Deep mud and wet rocks were home to the TSL's though. Buy some maxxis trepadors! I am thinking of giving them a try.

I have not heard anything good about the Treps. Lester hates them on this YJ. I have heard the Pitbull Rocker bias are extreamly awesome! :D

Now back to the op....
sorry!

[94Dodge Truggy]

I have not heard anything good about the Treps. Lester hates them on this YJ. I have heard the Pitbull Rocker bias are extreamly awesome! :D

Now back to the op....
sorry!

Pitbulls have worked well for me but are damn heavy!

[HumminNBoatin]

I had the 37" BFG KM1's and they sucked for sidewall strenght. I replaced them with toyo M/T's. Knock on wood the toyo's have NEVER had any problems on or off road. They even run better down the highway than my
KM1's did. The side wall on the Toyo is like 3/4" thick.

I also think the Goodyear Kevlar mtr is a good tire to look into.

You are not kidding on tire prices skyrocketing once you get to 35 and beyond...

[Coppertop]

After a few hours of research...I found three good front axle kits .(Clayton,Rubicon Express,and T&T Customs) I decided on the T&T.
http://02ea137.netsolstores.com/fronttruss-hpd44leafsprungstyle-1.aspx

I like the truss design (should save me a ton of mock up time),so simple even I can set it up.

The rear axle will have T&T'S u-bolt eliminator kit.
http://02ea137.netsolstores.com/u-bolteliminiators.aspx
My plan was to run a ladder bar(to prevent axle wrap)I understand ,with this design it will prevent axle wrap ..Again saving me time and money.

Nick

[boomhauer]

a competition compound trepador is prolly the best tire on the market but they are strictly offroad tires. km2's would be your best bet IMO.

[itbrokeagain]

$144 each. http://http://www.treadwright.com/shopnow/product/tabid/61/productid/81/sename/37x1250r165-guard-dog.aspx

[gothodgie]

$144 each. http://http://www.treadwright.com/shopnow/product/tabid/61/productid/81/sename/37x1250r165-guard-dog.aspx

link is not working correctly...

:beers:

[itbrokeagain]

http://www.treadwright.com/shopnow/entity/tabid/60/entityname/category/categoryid/43/sename/37x125r165.aspx


Linky linky

[Coppertop]

Heck of a deal...

Nick

[itbrokeagain]

Thinking about buying one for a spare

[gothodgie]

http://www.treadwright.com/shopnow/entity/tabid/60/entityname/category/categoryid/43/sename/37x125r165.aspx


Linky linky

I have looked at these a couple times and have researched the some and they seem to have a good track record for the last few years in the smaller sizes. The just don't many 15" choices in bigger sizes.

:beers:

[Coppertop]

The goods are starting to roll in.:thumbup:

http://i529.photobucket.com/albums/dd335/xjwheeling/jeepaxleswap007.jpg

Now,I need to get the engine and trans in the white car.Then the axle swap project starts.

Nick

[Coppertop]

Had a good day...Got my rear dana 60 stripped and cleaned for the machine shop.Going to have the housing shaved and reamed to fit 35 spline axle shafts.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap016.jpg

The rear disc brakes mount and clear the 16 inch wheels I have on hand(still waiting on the new beadlocks)
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap019.jpg

I decided to upgrade to 35 spline axle shafts.It's amazing the difference in size..
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap014.jpg
The original 30 spline axle is on the left.

Nick

[itbrokeagain]

Who is going to end up doing the axle work for you?

[Coppertop]

Who is going to end up doing the axle work for you?

Terry -TKH Fab ( the guy you hooked me up with) I wanted to have it there last monday.But the car from hell was still in the garage.:D

Planning on dropping it off tomorrow.

Nick

[gothodgie]

looking good... that is a great up grade on those shafts...:thumbup:

:beers:

[Coppertop]

I'm making progress.Still about two weeks behind schedule.The front truss from T&T Customs install went pretty well.Just a few highlights.
The axle must be stripped of all brackets.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap023.jpg
On the driver's side (two and three eights )of the cast spring mount must be removed.A 4 1/2 grinder with a cut off wheel done the job.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap017.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap018.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap020.jpg

The truss required some trimmimg to fit.All done with a hand grinder.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap035.jpg
The bottom LCA brackets were welded on after the top was welded in place.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap037.jpg

Back to the garage...:sweatin:

Nick

[94Dodge Truggy]

Excellent work! Going to be ready for west virginia?

[Tool Man]

Excellent work! Going to be ready for west virginia?

Looks good:beers:

[Coppertop]

Going to be ready for west virginia?

Yes Sir,I'm planning on it...

Nick

[yellowjacket]

Slick...:cool:

[WrenchMonkey]

Outstanding, man! Great work!

:beers:

Robert

[Coppertop]

Thanks everyone,Picked up my shaved and reamed Dana 60 rear end yesterday from TKH Fab.Terry done a great job..Can't wait to get it under the XJ..

Nick

[cincygman]

Looks awesome Nick! If you need some help with the problem car, I got some left over C4.............ahh nevermind:D

[Coppertop]

Looks awesome Nick! If you need some help with the problem car, I got some left over C4.............ahh nevermind:D

Thanks ,Funny you mention C4...I drove it(Ford Taurus) today, only to have a gas line start leaking.It was tempting to strike a match.....:D

As usual ,I pulled it in the garage and repaired the car from HELL.

Did manage to get the ball joints replaced on the Dana 44.

Nick

[Coppertop]

Making progress,rear axle installed.The rear shocks look long,not much travel.

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap002.jpg

A tad wider:D

I like the look of the T&T u-bolt eliminators.

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap006.jpg

Hope to get the front dana 44 installed this weekend.

Nick

[gothodgie]

those u bolt eliminater perches look sweet...

Keep up the good work...

:beers:

[93 Krawler]

those u bolt eliminater perches look sweet...

Keep up the good work...

:beers:

Yeah, they are sweet. That's the way to go. :thumbup:

[no mods]

those wheels gonna clear the calipers like you had hoped?

[Coppertop]

Yep,they cleared when I mocked it up on the bench..The 3.75 backspacing was the key..If I were to do it over again.Would go with 17 inch wheels.

Nick

[krawlin85toy]

lookin good.

[Coppertop]

Removed the Dana 30 and installed the Rough Country long arm system and the Dana 44 axle last weekend.Some early issues, the trac bar hits the front diff cover truss when the axle cycles upward.Hope to Fab a new bracket and relocate the trac bar bracket forward to solve the problem.The front shock mounts that came with the TnT truss kit won't work.I'm thinkin' bout just welding on some tabs.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap006-1.jpg

I like the way everything mounts up behind the axle increasing ground clearance.
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap017-1.jpg

I managed to get one wheel installed.Looks like more fender trimming...:sweatin:
http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap020-1.jpg

I hope to get all the issues solved and the steering links built this weekend..

Nick

[Coppertop]

Another sixteen hour day in the garage yesterday,results in a one mile test drive......... on the jack stands.Yeah, I know why bother.I now know the WJ brake booster and master cylinder upgrade I did a few years ago won't work with the bigger calipers. So,I'm searching for options.

Lookin' at the Dodge truck and /or Durango master cylinder option.Theres a few sitting at You pull.So....off to the savage yard I go.

Hope to have good news by the end of the day.

Nick

[Coppertop]

Think I figured it out(Just took most of the day). The afternoon started with a trip to the savage yard.I pulled the brake booster and pedal assy. from a 98 XJ .This will allow me to use a MC from a 1999 Dodge Ram truck.A trip to Advance Auto for the MC with the reservoir(Nothing at You Pull was worth buying) So the plan was to unbolt the old and bolt on the new..Then reallity kicks in(nothing comes easy for me)...:(

Pending mods:
Top pedal assy mounts won't match up
Rewire brake switch
The brake lines will need to be redone (too short)
The new master cylinder won't clear the hood( the cap hits)
Remount my on-board welder control panel so the brake lines will install in the MC

Maybe the good news will come next weekend .:D

Nick

[Coppertop]

Just realized I didn't post up the steering and trac bar info.I made the trac bar with 3/4 Ruff stuff heims and 1.375ODx.188 DOM with a 5/8 mount bolt.
The steering links are 7/8 Ruff Stuff Heims and 1.625ODx.188 DOM with 3/4 Bolts.They are pretty beefy..Can't wait to trail test them.

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap012.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap011-1.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/axleswap006-2.jpg

Looking for fender flare options...:confused:

Nick

[WrenchMonkey]

Badass, man. When do you wanna do mine?

You can't just move the TJ flares up?

Robert

Edit: Here's a thought: http://www.naxja.org/forum/showthread.php?t=1045189

[RuffedUpXJ]

What's your TB length and your draglink length? I ran the same setup for a week and ran into some bump steer and when the Jeep would roll I ran into some issues where the roll would cause the some understeer and felt unstable. I ran mine to the top of the tie rod to have the exact length TB and draglink. Just a thought incase you run into this issue. And crank the **** out of those bolts on the knuckles.

Looks good. Nice and wide.

[blazerbrad]

Looks good. Just one comment, on that stacked rod end steering do you think it will hold up okay? Just seems like a lot of leverage on that single bolt?

[Coppertop]

Badass, man. When do you wanna do mine?

Thanks,get the parts coming.We're make it a summer project.I like the idea of a flat fender flare in the NAXJA thread.The TJ flare outer lip is catching on the tire.Moving up is no longer a option.

What's your TB length and your draglink length?


Draglink 39 inches from center eye to eye.Trackbar 27 inches.At this point,I'm gonna give it a try,because the only way I see making them closer to the same length is making a complete new trac bar bracket and moving it forward on the frame.

Looks good. Just one comment, on that stacked rod end steering do you think it will hold up okay? Just seems like a lot of leverage on that single bolt?

Thanks,Great comment,I'm thinking the same thing..I've talked to a few guys running this set-up with no issues.Rusty's offroad sells a similar set-up that uses 5/8 bolts(I'm using 3/4 bolts).Time will tell..

I'm carrying spare bolts just in case.

Nick

[RuffedUpXJ]

When you move it forward and place it front of the spring I got mine to 33 inches and made the draglink that length as well/ Helped on road manners a lot.

[Coppertop]

Good Deal,Hope to give it a test drive this weekend.

Nick

[Coppertop]

The time is flyin' by ,I'm still working on the rigg.....:( Got the new brake system installed and gave it a test drive round the neighborhood last week.The brakes are way better,but I'm still not happy .So ,I ordered a adjustable porportion valve.While waiting on parts,I gutted the interior and finished the roll cage and reinforced the area under my roof mounted tire carrier.Then came the floor rust repair (still working on this).Hope to give it a highway road test very soon.
The rear seat has been removed for good.It's a two door two seater...:D

Nick

[gothodgie]

The time is flyin' by ,I'm still working on the rigg.....:( Got the new brake system installed and gave it a test drive round the neighborhood last week.The brakes are way better,but I'm still not happy .So ,I ordered a adjustable porportion valve.While waiting on parts,I gutted the interior and finished the roll cage and reinforced the area under my roof mounted tire carrier.Then came the floor rust repair (still working on this).Hope to give it a highway road test very soon.
The rear seat has been removed for good.It's a two door two seater...:D

Nick

can't wait to see it...

:beers:

[Coppertop]

I'm not able to reuse my OEM sway bar (to narrow), everything is in the way of mounting the brackets to the axle.Been looking around for ideas.Allthough ,the more I think about it.....With the wider stance ,it should be more stable.So, maybe I won't need one.

Nick

[Coppertop]

Got the rigg out of the garage yesterday for the first test drive.Hit 70mph on the Hwy with no issues.Then drove down East Miami River Road,I'm impressed with how it was handling the sharp turns ,almost like a sports car :D. I doubled the posted speed on most of the turns. I'm still on the fence about not running a sway bar.Overall ,I'm pleased ...Next,I'm going to finish installing the rest of the skids,rock rails,spare tire ,and all the gear I carry.Then run the same test.

:sweatin:
Nick

[itbrokeagain]

How did your brakes turn out? What did you end up doing?

[Coppertop]

How did your brakes turn out? What did you end up doing?

The brake system (a brief summary) 98 xj brake booster and pedal assy,99 dodge 2500 master cylinder,all wheel disc brakes,and Wilwood adjustable proportioning valve.
After installing the proportioning valve the brakes are good.

Nick

[itbrokeagain]

That sounds easy enough.

Why the Xj booster? I thought the upgrade was a Wj booster.
I assume you kept the stock metal lines.
Are the calipers on the rear 3/4 or 1/2 ton? I assume they are Chevy right?
How much fab work did the 2500 master take to mount up? Did you have to do anything to the pushrod?

Sorry for all the questions but I am trying to figure out what I am going to do.

[Coppertop]

That sounds easy enough.

Why the Xj booster? I thought the upgrade was a Wj booster.
I assume you kept the stock metal lines.
Are the calipers on the rear 3/4 or 1/2 ton? I assume they are Chevy right?
How much fab work did the 2500 master take to mount up? Did you have to do anything to the pushrod?

Sorry for all the questions but I am trying to figure out what I am going to do.

No problem Tony, glad to help. The dodge truck MC will not bolt to the WJ booster(bolt pattern not even close and hole to small)So,I had to go back to the XJ (98) brake booster and pedal assy. It bolts right up no mods needed.The push rod was replaced with a 1/4x2 fine thread grade 8 bolt with the corners rounded on the head.All brakes lines are standard 3/16 flare.I had to change out the ends on the MC side.The new Wilwood adj proportioning valve came with flare nuts to change out all existing lines.The rear are chevy calipers.I bought the kit from Shawn on Pirate.Nice kit everything you need to do the job.
The links that helped me figure it out.
http://www.naxja.org/forum/showthread.php?t=903864&highlight=XJ+upgrade+thread
http://www.pirate4x4.com/forum/showthread.php?t=746609


Hope this helps..:beers:

Nick

[Coppertop]

Loaded up the heep with everything I carry..Ran the same route(I-275and East Miami River Road).At one point reached 75mph..Handled really well ,with the only issue being body roll.
I'm convinced.....I need a sway bar.I'm wondering if a sway bar from a full size truck will work??

Back to the garage.:sweatin:

Nick

[gothodgie]

Cool... I am sure you are happy to have it on the road again...:D

How wide do you nead ? i have 2 fj60 sway bars... they are in my pile of parts, you are more than welcome to try one if you like... sway bars are for wimps.:evilgrin:

:beers:

[Coppertop]

Sweet,a yota sway bar will be a nice touch...:D The stock xj bar measures 37inches wide.If one of your's is at least 43-44 inches wide it may work.The wider one is needed to clear the coil springs.

I'm on vacation this week.Just let me know the best time to pick it up.Yes,it's getting close..Can't wait to hit the trail.:evilgrin:

Nick

[gothodgie]

the fj60 sway bars are only 36"s wide... sure looked wider than that laying on the ground... good luck...

:beers:

[Coppertop]

Thanks for checking....The search continues.

Nick

[Coppertop]

Been busy in the garage this week...Time for a update,with pics..
The Viair #1007 onboard air fit nicely behind the pass seat.It will supply air for the front ARB Locker and air the 36 tires.I built a removable metal frame to allow for a storage container above .You can barely hear it run.:)
http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap002-2.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap005-1.jpg

The roll cage got some yella padding.:D
http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap009-2.jpg
Also, installed a rear brake line lock(next to the T/C lever and ran the brake line inside to the rear.

Rear fenders needed a trim.
http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap004-1.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap014-1.jpg

I'm finishing the fenders today with some sheet metal to close up the bottom and black bedliner paint.

Build sheet coming soon..
Nick

[Coppertop]

The rear fender trimming is done and the rear shackle relocation brackets are on.I like ........:evilgrin:

http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap015-1.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/axleswap017-2.jpg

Back to the garage.
Nick

[RuffedUpXJ]

Move the shackle further towards the front on the relocation bracket, it will help achieve some angle which will allow more flex. I would say move up 2 holes if not three and put the leaf in the last hole on the shackle to maintain the height.

[Coppertop]

I'll give it a try...I can't wait to hit the trail this weekend.

Thanks :thumbup:
Nick

[WrenchMonkey]

Yeah, I've heard the same thing, that you want about 45* in the shackle.

Does look great man!

See ya

[Coppertop]

Thanks...Yeah ,my plan was to have the rear shackles dialed in by now.Then finish welding them and paint.Then,late sunday noticed the rear rotors had oil on them from the wheel seals leaking.I replaced them and drove it to work 60 mile hwy round trip yesterday.Checked again, still oil sprayed on the rotors.This time the seals are dry.I'm puzzled...

Thinking,maybe there was oil build up in the rotor cooling fins.:confused:

Nick

[Coppertop]

Overall,I'm pleased with the new set up.I'll start with the good.Love the Rough Country long arms,nice ride on the hwy and great trail flex.No bump steer and no vibs .Love the front slectable ARB and the lock out hubs.Very happy with the 513 gears.

The issues:
Lost MPG:( Averaged 13 mpg before the swap.Now it's at 11.5 mpg.
The rear springs are flattening out and flexing upward like there weak.:confused: This caused the pinion angle to be way off.At times the two yokes were contacting.I'm calling Rough Country first thing tuesday.
The rear wheel seals are still seeping.
The front tires are hitting the rear part of the fender when flexed out.

Happy to be out of the garage and on the trail.Even know it was just for a day.
http://i529.photobucket.com/albums/dd335/xjwheeling/Big%20Rock%20May%202011/BigRockMay2010076.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/Big%20Rock%20May%202011/BigRockMay2010125.jpg

Back to the garage.:sweatin:
Nick

[buckeyezuk]

The build turned out good man.. I am starting a xj build now. rear bump stops will help your uptravel problem. if you put a spring pack in that is stiff enough to not uptravel, it probly wont flex good either. a softer spring pack with bump stops is probably your best bet. a traction bar on the rear will help your springs live longer also. axle wrap will kill your leafs. you may have a traction bar but i didnt catch it in your build.

[Coppertop]

The build turned out good man.. I am starting a xj build now. rear bump stops will help your uptravel problem.

Thanks..Good Luck on your build.The rear springs seem to soft,after adding the rear shackle relocation brackets they are sitting almost flat (no arch).Rough Country has always been good to deal with so,I'll give them a call first.All your suggestions are good and I'm considering them.

If you have any questions on your XJ build.I'm happy to help.

Nick

[xj joey]

Looking good Nick!

[itbrokeagain]

I solved the flat spring issue on my yj with an extra main leaf under the original. A traction bar is a must.

[Coppertop]

I gave Rough Country a call ,they are sending me another set of rear springs...If that don't solve it ,then I'll start adding leaves.I agree with the traction bar..The u-bolt eliminators was suppose to help reduce axle wrap.I'm not seeing it so far.

Nick

[Coppertop]

Got the rear springs out. Man,did they flatten' out.

http://i529.photobucket.com/albums/dd335/xjwheeling/Jeremysdog186.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/Jeremysdog185.jpg

I'm gonna take the leaf under the top one out of the old ones and add it to the new ones.Hopin' it will add a little lift and stiffen them up.

Nick

[gothodgie]

did you get anything figured out for a sway bar yet?

It looks good in the pics from big rock... It doesn't look as wide ai thought it would..:thumbup:

[Coppertop]

Nope,I just havn't got a chance to address the sway bar issue.My plan,to go to You Pull and Save check all the full size trucks and suvs.It's pretty wide.:eek: I rubbed the tires a few times in some tight spots.

Got the new rear springs in..It looks alot better,even had to change the shackle postion.

Nick

[itbrokeagain]

When you heading out again? I would like to tag along in my Xj. My Yj is STILL not running well. Replaced every sensor, distributor, and swapped the fuel pump (pressure was a little low), and Swapped in another ECM. Now I am starting into the top end of the engine. Anyway mind if I tag along?

[Coppertop]

Heading down to Big Rock next weekend.Camping friday night and wheeling saturday.I started a thread.

Hope to see ya .
Nick

[Coppertop]

Went to Harlan this weekend for the SEC Naxja Cherokee Crawl.Man ,I put the heep to the test.Did'nt take long to break it....:D
http://i529.photobucket.com/albums/dd335/xjwheeling/Naxja%20July%202011%20Cherokee%20Crawl/NaxjaHarlanJuly11015.jpg

Heck,even got it on video.
http://youtu.be/-78N3NmGRaA

The second day.The front truss cracked at their welds.Glad I had the home made welder on board.

http://i529.photobucket.com/albums/dd335/xjwheeling/Naxja%20July%202011%20Cherokee%20Crawl/NaxjaHarlanJuly11055.jpg

http://i529.photobucket.com/albums/dd335/xjwheeling/Naxja%20July%202011%20Cherokee%20Crawl/NaxjaHarlanJuly11083.jpg

Another CORE member made it.Always a good time wheeling with beer googles 009
http://i529.photobucket.com/albums/dd335/xjwheeling/Naxja%20July%202011%20Cherokee%20Crawl/NaxjaHarlanJuly11039.jpg

Overall ,the rig performed well.I'm going to buy stronger alloy u-joints.:rolleyes:

Rest of my pics here.
http://s529.photobucket.com/albums/dd335/xjwheeling/Naxja%20July%202011%20Cherokee%20Crawl/

Back to the garage
Nick

[gothodgie]

looks like you had a great time... How was the weather, hot as he** ?

:beers:

[WrenchMonkey]

Did'nt take long to break it...

Back to the garage
Nick

Oh, that sucks!
They're still 297 joints, right? Same as you were busting on your 30?
Shame you weren't able to eliminate that proven weak link...

So can you change a 44 shaft as fast as you could a 30? :D

Robert

[Coppertop]

looks like you had a great time... How was the weather, hot as he** ?

:beers:

I had a blast.Yes ,it was nice n dry and hot.

Oh, that sucks!
They're still 297 joints, right? Same as you were busting on your 30?
Shame you weren't able to eliminate that proven weak link...

So can you change a 44 shaft as fast as you could a 30? :D

Robert

Not even close to the time ,I could change out a 30 shaft and never want to get that good with this axle...:D I'm going top of line, Bobby Longfield or Yukon super joints.Ordering them tomorrow,I'm hoping to get warranty replacement on the USA axle shafts,after all it was a USA alloy u-joint that broke.

Nick

[gothodgie]

bobby longs stuff is the only way to go in my opinion... he makes front axles for the yotas and i know a couple of guys with fj40's on 40" tires with some horse power and deep gears, and they beat on them with no issues... Can't beat a lifetime warranty either... :thumbup:

:beers:

[WrenchMonkey]

Oh yeah, I almost forgot: I guess the new leaves worked better?

Is this the first time you've had em out on the trail?

Robert

[Coppertop]

The only problem with the rear springs,the bushings are noisy.I won a Rusty's Offroad 250.00 gift card at the raffle.I'm thinking about using it towards a set of rear springs.

I talked to several people and they all said good things about the Bobby Longs stuff.So, I'm ordering those joints.

I'll get this thing built right...One of these days.:evilgrin:
Nick

[frankensteinxj]

Hey Nick im about to swap some one tons in my xj.

i came back to check out some pictures of your setup but a lot of them arent showing up.

i will be using the rc long arms as well which is why Im lookin at your build specifically.

How did you figure out where to mount your upper control arm mount?

How long did you setup your upper and lower arms.

definately one of my favorite xjs man.
Good work.
:beers:

[Coppertop]

Thanks man...Good luck on your swap.
Heres a link to all the pics.
http://s529.photobucket.com/albums/dd335/xjwheeling/Axle%20Swap%202011/

I went with the TnT front truss.All the brackets(except the lower control arm , shocks and sway bar brackets)are installed and welded in place by them.The truss comes with instructions to install it and to mount the lower control arm brackets.
http://02ea137.netsolstores.com/front.aspx

I setup the RC control arms per their instructions.The uppers measure 15 1/4 inches from eye to eye.The lowers measure 29 3/4 from eye to eye.

Nick

[kentuckytwostep]

I use to have a ford 44 under my old XJ, got to where I could change out a U-joint in about 30 minutes... did it 3 times at Dixie Run last year. Also had RC rear lift springs in the rear and one of them wrapped my first trip out. anti-wrap bar is a must.

[Coppertop]

That's pretty quick....I could switch out one in my old dana 30 in 20 minutes.After breaking a front USA Alloy joint at Harlan,I bought a set of Bobby Longfields Super joints.So far they are holding up..Beat it in Attica(Badlands) a few weeks ago with no issues in the drivetrain.I justed replaced my rear RC springs with a new set from Rusty's last week ,all the bushings were wiped out.

I hope to post a build sheet soon.:D

Nick