88 YJ-CJ Axle and Suspension Planning

Axle and Suspension Planning

As I get closer to getting the engine running, the driveshafts, axles and suspension have gotten more thought and attention. The driveshaft lengths will be affected by the axle and suspension, and driveshafts are expen$ive!  If I want to do any axle swaps or changes now is the time!

Front Dana 30

The Jeep came with a stock YJ Dana 30 with 4.10 gears. 

The previous owner installed a "Posi-Lock" to actuate the Central Axle Disconnect (CAD), which replaced the stock vacuum actuator.  I'm not a big fan of the Posi-Lock and the extra cable into the cab.  A common upgrade to to install a one-piece passenger shaft out of a TJ or XJ.  Unfortunately, I haven't been able to find a good, reasonably-priced one-piece shaft. I  don't really want to spend for a new chromoloy passenger shaft or a complete set of front chromoly shafts ($600). 

I don't know the condition of the Dana 30, so it may need more work like ball joints, unit bearings, tie rod ends, brakes, rotors, u-joints, etc. I've rebuilt a Dana 30 before with stock parts, and it gets fairly expensive. 

I need to pull the Dana 30 to cut off the SOA perches added by the PO. It could also use some paint.


Front Wagoneer (Waggy) Dana 44

A Waggy Dana 44 was included with the Jeep when I bought it.

The previous owner had done some work to it:

  • converted to 5 x 5.5
  • lunchbox locker
  • new Warn locking hubs
  • new brakes but with light surface rust on the rotors
  • setup for crossover steering with a high steer arm on the passenger side
  • I'm not sure of the gearing - I think it has 4.56 in it right now.
Waggy perches are offset from the YJ frame by 1/4" on each side, so I'll have to do some minor fab work to fit it into the YJ.

New Warn Hubs


It has a high steer arm on the passenger side:


This Dana 44 is interesting for 3 main reasons:

1) Since, I'm doing the CJ7 conversion, the 5x5.5 lug pattern with front locking hubs will look much better. And will also allow CJ7 classic wheels to be used.

2) Crossover-steering

3) Better brakes and somewhat stronger

4) It might be cheaper to just swap in the Dana 44, than to rebuild the Dana 30.


Rear 8.8:

The Jeep has an 8.8 out of an Explorer. 


The good:

  • Good, strong axle. I'm very familiar with them
  • Supposedly it has a Detroit locker in it and 4.10 gears

The bad...it needs quite a bit of cleanup:

  • the brakes lines are ridiculously horrible
  • it has a ladder bracket and SOA perches that need to be removed
  • the shock mounts are iffy - I might need to move them. 
  • It would need to be converted to 5x5.5 if I go with the Dana 44.

Horrible Brake Lines

Suspension:

The suspension is important for the rear pinion angle and driveshaft length.  I still need to weld on the rear SUA perches to set the pinion angle.  

Currently the Jeep has a set of older Rubicon Express 1.5" SOA springs.  Since they are older, they don't have the reverse eye wrap like the newer RE 1.5" SOA springs. The PO put an extra leaf into the rear pack - probably to prevent axle wrap, so I'll remove that extra leaf.  His welding on the rear leaf spring brackets left quite a bit to be desired.  


The Plan:

Suspension:

  • Buy new OME 2" leaf springs for front and rear.  I actually already purchased them.  I didn't want to spend the money, but I couldn't run those crappy old leaf springs.    




  • Buy some cheap shocks - I'm thinking Skyjacker Hydro 7000 - they are cheap!



Front Axle:

  • Pull the Dana 30 and sell it - the 4.10 gears should make it desirable.  It would help offset the costs of the other changes.


  • Install the Waggy Dana 44 - modify the perches, re-gear to 4.10, clean up the rotors, buy and install crossover steering - the costs will be partially offset by selling the Dana 30.



Rear Axle:

  • Drill the 8.8 axles and rotors to 5 x 5.5 if possible.  One company makes a neat drill guide, which I could either buy or copy the design and make my own.  It's iffy if there is enough meat in the axle to drill 5x5.5.  

If I can't drill the axle shafts, I could buy a set of new axles with c-clip eliminators that have 5x5.5.  Not ideal...$$$.    






Wheels:

  • Use a set of 5x5.5 Turbine wheels that I have. I like them a lot. Classic, old school.  If I don't use them on this Jeep, I'll probably use them on my 95 YJ.  


Future:

  • In the future, put a selectable locker in either the front or rear. Off-roading with automatic lockers front and rear isn't ideal - I'd expect maneuverability to be very poor.
  • A front Eaton Dana 44 eLocker would be nice: