Well my d35 is toast.

What all is needed to do a 8.25 swap?

Vehicle is a 91 xj cherokee with a 3" rough country lift

 

The 8.25 bolts right in. Look for the stronger version from a 97+ with the 29 spline.

 

You may need a different driveshaft. The 8 1/4 is a little bit longer.the 97 and later have 29 spline axle that are 1.21 the 96 and earlier have 27 spline ad 1.17 spines.

 

And make sure its the same gear ratio as what you have now.

 

When doing this swap its a good idea to upgrade the rear drum brakes to discs and a member here Big Davis sells a used complete kit to do so using all factory ZJ parts a mid 90's V-8 setup, very reasonable.


You can PM him here for more info. both of these rear/brakes are really nice upgrades.

 

Also new u bolts since they are one time use, and it would be a good idea to install a locker and/or aftermarket cover while it's off the jeep.

 

May as well throw on a longer brakeline while you're at it, I have a YJ rear line on mine, I've heard a Dakota rear line is about 6" longer while the YJ line is about 3" longer, bolts right up and is only like $25 at the parts store. Good way to make sure you don't blow out the line while offroad to accommodate for your lift.

 

Also if you have ABS you'll need to pull the fuses and relays which you can find in the owners manual where they are so you don't get a check engine light after you cut the wires. Chrysler 8.25s don't have abs.

 

How long of a U bolt do you need?

 

http://m.summitracing.com/parts/cur-...GMthoCw-bw_wcB

Get 4 of these, I have them. If they're too long cut them shorter once installed.

 

What's the best way to make sure the axles and diff are in good shape? Worth pulling the diff cover?

 

Definitely, that's the only way to know for sure.

 

If I remember correctly any year 8.25 can be put under any XJ. Its a direct bolt in. Just make sure to get the same gear ratio. I know most are 3.55 but you never know. Just like others have said, go for the later 8.25, its 29 spline. You SHOULD get new u-bolts, its not necessary, but its a very good idea. Im still rocking used u-bolts.

 

He will have to get new bolts as 8.25 is a larger diameter tube.

 

Just use the u-bolts from whatever XJ he pulls the 8.25 from