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Author Topic: Ford 8 8/9 hybrid  (Read 7108 times)

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Offline codykoke

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Ford 8 8/9 hybrid
« on: January 31, 2015, 07:33:54 PM »
I have been planning a new axle build for my tj for quite some time. I'm tired of fixing the d35 after every wheeling trip. My initial plan was the 8.8 conversion out of an explorer. One con of this would be that it uses c clips to retain the axle. After snapping a c clip shaft at the farm and spending hours getting the jeep to level ground I've decided against this swap. My next choice was to run a 9". This would have eliminated the c clips and added a stronger gearset with an extra pinion support. However I don't care for the super low pinion and finding one of appropriate width and 31 spline proves to be a challenge. So I have decided to narrow an 8.8 out of an f150 I have lying around and weld 9" housing ends on and run 35 spline 9" shafts with a spool. Overkill for 33's or 35's absolutely, but I won't have to worry about it. I picked up the 8.8 last year for 10$ since the gears were shelled out of it. Here's the shopping list as of now.
-chromolly 35 spline cut to length shafts
-35 spline spool
-4.56 gears and install kit
-9" housing ends
-caliper brackets and brake parts

Most of these parts I will be buying from quick performance in Ames.

First up on the agenda was to sandblast the axle and since a coworker needed to sandblast some stuff of his own I figured I might as well start today as well. After a couple hours in the rain I finally finished, but two hours in the rain sandblasting beats 10 min with a wirewheel. Here's a pic of the axle all stripped down ready for blasting.
« Last Edit: January 31, 2015, 07:48:54 PM by codykoke »
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #1 on: February 04, 2015, 06:44:22 PM »
Welded the tubes to the chunk and started designing a truss. My plan is to triangulated the uppers on the pumpkin and weld new brackets frame side.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #2 on: February 07, 2015, 08:43:53 PM »
Got the brackets cut off and started the truss. Also spent most of the day calculating the four link. With the help of adjustable brackets I got my numbers right so they will work with my current 33's and 35's down the road. For some reason tapatalk isn't uploading pics right now so just imagine an axle with brackets cut off.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline nelson

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Re: Ford 8 8/9 hybrid
« Reply #3 on: February 07, 2015, 08:56:02 PM »

For some reason tapatalk isn't uploading pics right now so just imagine an axle with brackets cut off.

Looks great!


Sent from my iPhone using Tapatalk

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #4 on: February 08, 2015, 10:13:24 AM »
here's where I'm starting today.
« Last Edit: February 08, 2015, 10:18:20 AM by codykoke »
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #5 on: February 08, 2015, 04:13:18 PM »
Got the truss done minus some grinding. Used 1/2x3 bar stock.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #6 on: February 25, 2015, 08:02:33 PM »
Got the lower arms built tonight. Gonna run the duroflex joints I had left over from the red headed stepchild.  Running a midarm single triangulated rear with slightly inboarded coils and outboarded shocks.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #7 on: February 28, 2015, 07:11:24 PM »
Got the 35 spline spool today.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #8 on: March 01, 2015, 06:38:09 PM »
Got the arms painted and part of the housing. Hopefully my parts will show up tomorrow and  I can start the regear.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline pvanweelden

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Re: Ford 8 8/9 hybrid
« Reply #9 on: March 01, 2015, 07:26:40 PM »
Is that por15? Looks good!
JKUR, 35's, slabs, York oba, 3" enforcer, DL flip, bumpers, sliders, lots of switches, heated seats
TJ 4" lift, D44 LSD, ZJ Disc, 4.88, HP30 trussed, Spartan, 36" swampers, tube fenders, rear armor, sliders, custom rear bumper w spare tire, ammo cans, jerry cans,  smitty stinger, RC tie rod, steering box brace, skid, Currie AntiRock, SYE, LED's

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #10 on: March 01, 2015, 07:28:02 PM »
Nope just good ol rustoleum  brush on.  Does it still look good?
« Last Edit: March 01, 2015, 07:31:51 PM by codykoke »
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline pvanweelden

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Re: Ford 8 8/9 hybrid
« Reply #11 on: March 01, 2015, 08:57:19 PM »
Yup still looks good :)
JKUR, 35's, slabs, York oba, 3" enforcer, DL flip, bumpers, sliders, lots of switches, heated seats
TJ 4" lift, D44 LSD, ZJ Disc, 4.88, HP30 trussed, Spartan, 36" swampers, tube fenders, rear armor, sliders, custom rear bumper w spare tire, ammo cans, jerry cans,  smitty stinger, RC tie rod, steering box brace, skid, Currie AntiRock, SYE, LED's

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #12 on: March 02, 2015, 11:18:54 PM »
Gears and install kit showed up today. Unfortunately the gears were mislabeled in the box and were for a different axle. Big thanks to Quick Performance for resolving the issue so quickly. Correct gears will be here tomorrow. I did get the housing cut to width. Gonna run 63" wms to wms incase I ever step up to 37's
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it

Offline greentj4jc

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Re: Ford 8 8/9 hybrid
« Reply #13 on: March 03, 2015, 06:22:38 AM »
Very informative; thanks!
It's a rock - get over it

Offline codykoke

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Re: Ford 8 8/9 hybrid
« Reply #14 on: March 03, 2015, 11:36:00 PM »
Got the correct gears and most of my brackets from Barnes 4wd today. Started setting the gears up tonight and will hopefully finish tomorrow night and weld the lower control arm mounts on.
'98 TJ, all the basics and none of that fancy sh!t
'92 YJ, half the basics and that's it