XJwonders

I had a couple of d35's. They were exactly 2.75

SteveMongr

Aftermarket covers strengthen the pumpkin and helps hold the internals in place when under load. Also, they will not dent or crush when you bump an obstacle, the stock covers will. And the fill plug is often higher to accommodate an increased pinion angle. Good investment, front and back. I run Riddler covers.

ExpeditionXJ

Good to know. Thanks!

ExpeditionXJ

I just read I can swap over my D35's brakes... I'm going to look into this some more. I don't feel like spending $300+ and tracking down ZJ parts. The previous owner claimed the brakes on my jeep were recently overhauled. I guess l find out when I pull the drums.

SteveMongr

Forum member Big David is a provider of the ZJ brake kit, in the for sale section.

Fred/N0AZZ

One thing I did want to point out on the aftermarket covers is not to fill them like a stock one or it will be over filled due to the larger capacity. Steve's point is valid also and one I should have mentioned.


Jared are you still not planning on installing lockers along with the gears? I have Detroit's on the street for many years now in high and low HP apps 2/4wd never had any issues. JMHO The single best upgraded I made on my XJ was gears and lockers bar none.


Glad to see your moving along with your build.

ExpeditionXJ

Thanks for the heads up! I'll check it out.

ExpeditionXJ

Thanks for the heads up with the diff covers!

I don't have the funds for lockers.

My suspension build, SYE & driveshaft, wheels & tires, axle, etc will run about $5k and almost deplete my "jeep fund".

I honestly don't plan on wheeling too hard... this is more of a trail/ expedition rig that I've already gone way overboard with.

The 8.25 I got already has 4.10 gears in it. It was just delivered and I'll post pictures soon. It looks like it's in good shape.

I'm planning on having the front re-geared to 4.10. I was quoted $350 labor which seems fair.

I have plenty of time to reconsider though...

My suspension wont get here until mid next month. I have it to install, a rear main seal, SYE and driveshaft, and some other things. I'm going to go at this leisurely and only on weekends. It will be 100*+ here for the next couple of months so I won't be doing any 12+ hour days in the garage. I'm shooting to have the jeep derivable by mid October (wait period for custom drive shaft factored in).

DJeXeCute

If you use the d35 driveshaft you can get away with 4.5 inches of lift without a sye and maybe more.

ExpeditionXJ

I thought the D35's longer shaft and 8.25's longer pinion housing would allow a higher lift without issues. My rear lift will be around 4.5", but I assumed it was too high for it to make a difference. Thanks for posting that. I guess I'll hold off on the SYE and see how it turns out.

Thanks!

Fred/N0AZZ

For the differential being out of the Jeep $350 seem a bit high to install gears I paid $200 each for mine in the Jeep with the lockers.


At the least you might consider a lunch box locker for the front for a couple of hundred bucks no extra labor at the time, any kind are better none front or rear.


I leave mine in 2wd with the rear locked till it gets tough going then only go to 4wd. I found that I could go as far with the rear locked as I did before in 4wd.

ExpeditionXJ

Don't get me wrong I'd love some lockers. My new rear diff is 4.10, out of the car, and doesn't need a regear . The front is the one that needs to be regeared and is in the car. If it were the other way around I'd gladly install a locker.

I'm pretty sure the quote for $350 was for the diff/ axle on the car. I'm planning on seeing how much money can be saved if I uninstall the front axle for them. I'm also curious if I can do any of the differential disassembly to save money.

The fact that DIY regears are so taboo makes me want to attempt it even more. I've been reading multiple guide and I'm aware it requires expensive tools, extreme precision, is very easy to scew up, and conventional forum knowledge is extremely opposed to it... But if I can find someone to double check my work along the way it would make a good winter project.

But I'll probably puss out and spend the winter teaching myself how to weld.

Motowmat

If your going through the trouble of swapping rear ends do what I did and put an 8.8 limited slip from a explorer in it. Already has factory disc brakes and its way stronger and is limited slip and the limited slip works excellent. I bought a swap kit on eBay welded the new perches on and bolted it in.

Fred/N0AZZ

Hey man this is just a thought but if you did the complete tear down and gear install if you pulled it out then take it to someone to set the pinion depth, back lash, etc. just a loose setup I bet it would be a lot cheaper. You will need a new carrier for the D30 using the 4.10 gear or a full spool locker. You might save enough to buy a locker for the front if you can the XJ that long to do the front.


Those with more knowledge please chime in as I have had mine done.

ExpeditionXJ

That's exactly what I'm thinking. Or do it and have them check the specs. I already have a 20 ton shop press which is one of the more expensive tools needed.

I need to finish a couple of projects around the house this weekend. If I have time I'm going to pull a shaft on my new 8.25 to verify its 29 spline (it should be as its from a 99), and pull the drums to check out the brakes. The gears look solid.