First off, since this is my first post, hello. And I'm going to try to be comprehensive as possible.

I've been reading around all day about this and can't find the answers I'm looking for.

I was thinking of swapping my D35 for the 8.25.I've heard it's easy and worth it and I have a Upullit JY that sells axle assemblies for $89.

This is in a 1990 2dr 2wd 5sp XJ with 190000 miles on the chassis. Everything bolted to the undercarriage is covered in rust, including my rear brake hard lines which makes me uncomfortable. I know I can replace them but I'm looking at other options. The body is in respectable condition as far as rust goes.

This is my daily driver and my towed vehicle behind my RV which I live in full time. I will also have a 300lbs motorcycle on a hitch carrier when travelling. The Jeep sags about 2 inches with the bike on the back and without it I have about 3/4 inch of sag already at all 4 corners. That's another problem but I've got plans for that. My concern was the extra weight.

So, would it be worth it for the swap? I hope to do some off roading as I travel the country. Obviously nothing crazy since it's only 2wd but with a locker/LSD/etc/whatever I should be able to get some places. I really just want to be more capable then a 1wd truck. I also do not plan on lifting the Jeep but we'll see how long that lasts. If I did it would be nothing more then 2 inches.

Besides being worth it or not if I did do this the problem I've run into is the DS length. If I can should I pull it from the donor vehicle or will my stock DS be fine. That is if the donor Jeep is a 2wd 5sp. Would a 4x4 DS be better, I'm assuming it's shorter.

The other options I'm considering are just getting a better condition 2x4 or 4x4 XJ but I can't find a 2dr 5sp right now. I really don't want an automatic or 4 doors. On time is not on my side as I plan on hitting the road in the next month or so. I've also though about finding a totaled 4x4 as a donor and swapping it all over. That's another story though.

Thanks guys.

 

put a locker in the d 35 and call it a day. unless you want to run bigger than 31 inch tires the d 35 is just fine. If you want to do the swap, 5/8th's of an inch was what I took out of my drive shaft and that put it perfect on the yoke.

 

Thanks, that was another option and probably the option I'll end up with. I can replace the brake lines cheap and easy. I was thinking if I could find a 8.25 in better shape then my current axle at the JY it might be worth it.

 

you also will want to find a 97 or newer cherokee with the 8.25 because that is the 29 spline and the older 8.25's are 27 spine and not as strong as the d35

 

That I am aware of. The JY had a 97+ when I was the last week but I wasn't thinking about axles. I've got tomorrow off so I'm probably gonna head back there and see what they have. After taking another good look at my Jeep in the morning.

I Have no intension of going bigger then 31s so is theres no reason I may just save myself the time and work on something else. I've got plenty of other little stuff I can fix.

 

definatly start with the little things and work up to a axel swap. If you think you are gona need the new rear end then get it and when you get a week of time that you wont need the jeep, swap it in. Take the time to get the right drive shaft because that is the hardest part. finding the right doner can be hard but it can be done or you can do some measuring and have one built.

 

That's my usual plan with any vehicle. Get it running right then start changing parts. However, I've got a garage to use for the next two months then I'm on a two year plan to RV around the US. If I was gonna do the swap, now would be the time.

From what I'm finding out now it doesn't look like it'll be worth it. I not concerned about big tires but the weight on the axle with the moto on the back. It's only 300lbs but it's hanging over a foot off the back. After looking at what some people put on their rigs the extra doesn't seem like it will be a problem.

Thanks for the advice so far!

::EDIT::

Did some math, the 300lbs moto plus the 40lbs carrier will add about 500lbs to the rear axle. These weights are all generous numbers that I rounded up so it should be less then that but not by much.