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Old 06-29-2009, 05:15 PM   #1
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Default XJ Drum to ZJ Disc brake conversion

I asked some questions on here and many of you were quite helpful. Thanks! I'm injured so amything I do is at a snails pace. I'm getting ready to search the junk yard for my conversion pieces. I thought of a few more questions.

1) My Cherokee is a 1989 XJ. I assume it has a tapered bearing without the "C" clips. Will my getting a non tapered axle shaft with C clips be wrong? Do I need to stick with a tapered shaft? Maybe it only depends on the bearing and I need to switch to a non tapered bearing?

2) Will all ZJ Dana 35 axle shafts fit my XJ? I think mine is a 27 spline, but I'll pull it apart before venturing for parts.

3) If I'm using stock wheels will I need to put longer lug nuts in?

4) While I have the axle's out what should I replace? Seals and bearings?

5) If I decide to buy new rotors and calipers would I need to buy ZJ stuff for the new rear stuff?

Thanks!

Last edited by DearJimmy; 06-29-2009 at 05:17 PM. Reason: another added question
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Old 06-29-2009, 05:42 PM   #2
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This is my opinion but if you have a Dana 35 then do not spend money on it (It is like a good looking girl that makes you think you are going to get some if you take her out a couple times and then BAM she won't answer your calls anymore). I would at least find a 8.25 or even a d44 or 8.8 and spend the money on them they put out.
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Old 06-29-2009, 05:54 PM   #3
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This is my opinion but if you have a Dana 35 then do not spend money on it (It is like a good looking girl that makes you think you are going to get some if you take her out a couple times and then BAM she won't answer your calls anymore). I would at least find a 8.25 or even a d44 or 8.8 and spend the money on them they put out.
I researched the Dana 35 and found it said that it's a fine rear end if you're not using 31+ inch tires or off roading much. Money is a HUGE factor so I'll be sticking with my Dana 35.
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Old 06-30-2009, 01:44 PM   #4
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I researched the Dana 35 and found it said that it's a fine rear end if you're not using 31+ inch tires or off roading much. Money is a HUGE factor so I'll be sticking with my Dana 35.
Research again cause the Dana 35 is a TURD! I had a TJ I got it used with only 45,000 miles and I was the second owner and the first did nothing to it (meaning it was just driven regularly) I put a set of 32"x10.5 on it and drove it two days on the street and the spider gears turned to chunky peanut butter! It never even went off the road! I never even put it in 4x4! That was my worst experience but I have had at least 6 35's explode under little pressure. You can get a good C8.25 for $100-$150 and you can do the same disc brake swap to it and it stock is 100000 times better the the turdy five. But if you still stick with it than do not do a disc brake swap with out up grading the booster and master cylinder also. Good Luck
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Old 06-30-2009, 02:25 PM   #5
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But if you still stick with it than do not do a disc brake swap with out up grading the booster and master cylinder also. Good Luck
Do you know what I do if my bearings are tapered and the new axle's aren't? Do I only need to change to newer non-tapered bearings?
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Old 06-30-2009, 04:17 PM   #6
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if you want cheap and easy go the ford 8.8 out of the exploders with the disc already on should only cost 100 to 150 bucks and it has the same bolt patters then you just need to get some spring perches and shock mounts welded on you can probably do this for under 250 to 300 and that is the best cheap upgrade you can do that will get you a killer rear end with disc to boot. plus you can trash the Dana 35 that thing is a turd waiting to explode on you one day. we where just wheeling the other day and came across a tj with some 31's with a blown shaft and he had to limp it to the camp and do you know what it was a turdy five
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Old 06-30-2009, 04:27 PM   #7
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Do you know what I do if my bearings are tapered and the new axle's aren't? Do I only need to change to newer non-tapered bearings?
i think you can but wait till some body with a 35 chimes in i am unsure
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Old 08-22-2010, 02:02 PM   #8
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Quote:
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I researched the Dana 35 and found it said that it's a fine rear end if you're not using 31+ inch tires or off roading much. Money is a HUGE factor so I'll be sticking with my Dana 35.


My 90 has a D35 I installed a Powertrax no Slip Locker have been out 4 wheelin through a lot of rough trails and pretty good sized rocks and have had no problems with it. I do run 30 inch BFGs
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Old 08-22-2010, 07:59 PM   #9
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Look up "rear brake conversion", many topics and write-ups about it.

On a side note I would switch up to at least an 8.25 or 8.8 explorer which already has rear disc brakes. just some options.
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Old 04-15-2012, 07:01 PM   #10
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Dana 35 is not the best thats true. But i have been running mine to death all over! Thru Deep mud, Over Rocks and deep snow. hears the trick... use HD Gear Oil from Lucas, And change it often, about 3 times a year. And I run 31 X 10.5
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Old 04-15-2012, 07:43 PM   #11
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Dana 35 is not the best thats true. But i have been running mine to death all over! Thru Deep mud, Over Rocks and deep snow. hears the trick... use HD Gear Oil from Lucas, And change it often, about 3 times a year. And I run 31 X 10.5
Welcome to the forum jdub! I see this is ur first post.
And way to bring a thread back from the dead
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Old 04-15-2012, 09:12 PM   #12
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if you do the conversion to the 35, you can always swap it over to your other axle. not like its suddenly gonna vanish if you swap to a 8.8/d44/8.25 at any point.
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