At lunch today going to look for an 8.25 to replace my D35.

-I have an 01, do I have to get a 97+ 8.25?
-Did all the 97+ 8.25s have 29 splines, & will a 27 spline work worst case?
-I am pretty sure I have 3:55s, did all XJs come with the same gears?
-do all the brake lines/shocks line up, or is there fabbing?
-Do I need to get the driveshaft?

Thanks

 

-Ideally you will want a 29 spline. I would look for 97' and up. If you were closer, I have one sitting in my driveway.
1991 – 1996 : Chrysler 8.25", c-clip, non-ABS, 27-spline axleshafts.
Late 1996 – 2001 : Chrysler 8.25", c-clip, non-ABS, 29-spline axleshafts.

- Not all XJ's have the same gears, but I believe most 4.0L Automatics have 3.55

- Brake lines and shocks should bolt up fine. The backing plates are different if you plan on swapping brakes from your D35.

- The driveshaft u-joint at the axle yoke should be the same. The 8.25 yoke is about an inch closer to the transfer case, but I would try to use your existing driveshaft.

Two other things to be aware of:
1. You may need to do something to disable ABS, but maybe someone else can chime in here.
2. U-Bolts will be a different size because the 8.25 axle tube diameter is larger(3"). U-bolt plates should still work because they have elongated holes.

 

Thanks , very helpful. I ripped my ABS lines off on accident a long time ago and haven't had an issue. I already knew about the ubolts, not a biggie and I have a ZJ Disc setup in my garage ready to bolt on.