Jump to content
Sign in to follow this  
dzJeepChic

Clifford's Front Axle Swap - Installing a 2005 TJ Rubicon D44 in a '92 XJ

Recommended Posts

We bought both axles with the original factory lockers and 4.88 gears out of a 2005 TJ Rubicon. We were able to sell the rear axle to a guy in Tucson. This is Clifford's new front axle when we first got it:

 

DSCN6854.JPG

 

Since purchasing it George has been getting it ready to install in Clifford. He had to cut off some of the brackets and install new brackets for the XJ. He also installed a new ARTEC Industries axle truss and control-arm mounts, and some new C-Gussets from Iron Rock Offroad.

 

DSCN0002.JPG

 

ARTEC Industries axle truss:

 

DSCN0001.JPG

 

DSCN0010.JPG

 

DSCN0013.JPG

 

DSCN0014.JPG

 

DSCN0015.JPG

 

DSCN0017.JPG

 

DSCN0021.JPG

 

Yesterday George had to pull the carrier and install axle tube seals.

 

DSCN0018.JPG

 

Yesterday George hooked up an air-supply and demonstrated the locker for me:

 

 

We're keeping Clifford's original rear Currie built D44 axle with chromolly 33-spline axle shafts. Last week Clifford visited 4Wheel Supply where they installed 4.88 gears and replaced the Detroit locker in the rear with and ARB locker. We already appreciate that the Jeep doesn't go pow & pop when slowing and turning, and I'll never miss the rear-end wiggle you got whenever you took your foot off the gas going down the highway!

 

10499632_10204434869254736_4425840367711902025_o.jpg

 

Today George is painting the new front axle, and tomorrow Clifford's going under the knife.

Share this post


Link to post
Share on other sites

Nice work G!

Share this post


Link to post
Share on other sites

We got a lot done today. And I helped! :D

 

Clifford, say "Ah!"

 

DSCN0024.JPG

 

Out with the old:

 

DSCN0028.JPG

 

DSCN0030.JPG

 

DSCN0051.JPG

 

And in with the new:

 

DSCN0027.JPG

 

DSCN0055.JPG

 

Had to move the Rock Krawler upper control-arm bushing to the new pumpkin mount:

 

DSCN0059.JPG

 

It was pretty tricky getting the new one into place:

 

DSCN0060.JPG

 

Lower control-arms attached:

 

DSCN0061.JPG

 

Springs in place:

 

DSCN0063.JPG

 

Upper control-arm attached:

 

DSCN0064.JPG

 

We got it mocked up!

 

DSCN0066.JPG

 

Up next: passenger side upper control-arm link, Yukon spin-free hub kit install (thanks LetzRoll Offroad!), Synergy ball-joint install and putting it all back together. I see a shake-down run in my near future. :cool:

Share this post


Link to post
Share on other sites

It's been a while since I posted up because after we had the axle under the Jeep and George began to assemble it, he found out it was bent. It wasn't going together right so he began measuring things and sure enough, it was bent.

 

DSCN0070%2520-%2520Copy.JPG

 

So we had to pull it back out, pull the carrier, and then we took it to Arizona Differential. We had visions of them telling us there was nothing they could do, but we were wrong - they straightened it right up!

 

Here's a picture looking down the tube after we got it back:

 

DSCN0080%2520-%2520Copy.JPG

 

Now we were back to where I left off!

 

DSCN0082%2520-%2520Copy.JPG

 

And then George started putting it all together.

Share this post


Link to post
Share on other sites

After all the guts were put back in and the axle was back under the Jeep, George installed [i'm probably missing something here] new ball-joints and the new Yukon Hardcore Locking Hubs:

 

DSCN0093%2520-%2520Copy.JPG

 

DSCN0084%2520-%2520Copy.JPG

 

DSCN0086%2520-%2520Copy.JPG

 

DSCN0088%2520-%2520Copy.JPG

 

DSCN0089%2520-%2520Copy.JPG

 

DSCN0090%2520-%2520Copy.JPG

 

DSCN0091%2520-%2520Copy.JPG

 

DSCN0094%2520-%2520Copy.JPG

 

DSCN0104%2520-%2520Copy.JPG

 

Clifford's finally back on wheels now - which was a whole 'nother fight! After several used sets have failed to suit our purpose, new wheels are on order at Discount and should be here anyday.

Share this post


Link to post
Share on other sites

George is the man! This should clear up any overheating problems

Share this post


Link to post
Share on other sites

George finally got Clifford all buttoned up, the steering is on, the track-bar is centered, the air compressor for the front locker is mounted, wired and hooked up to a switch in the cab, the front sway bar connecting tabs are welded into place and we got new wheels that fit correctly! The sway bar disconnecting pins need to be re-located...

 

DSCN0131.JPG

 

DSCN0132.JPG

 

DSCN0133.JPG

 

DSCN0134.JPG

 

Sorry so blurry, he was raring to go and wouldn't hold still for the picture. ;)

 

DSCN0136.JPG

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
Sign in to follow this  

×
×
  • Create New...