'90Cherokee

I know there's already 3.758 million characters painstakingly typed about this but my search powers aren't revealing them. My only question is about the driveshaft, what has to be done to make that connection? I have no plans for a big lift or SYE and would use my shaft if it's possible or use the cheapest replacement option. I've completely eliminated my ABS so that's no concern either. I probably don't even need to replace my D35 but it's due for refreshing (making some noise) and throwing money at it seems somewhat wasteful when I can get a better axle, and especially the brakes, for about what it'd cost to refresh the 35.

Atmos

here's how you do it. other companies carry this product as well. but that's what you need. I think seriousoffroad and a couple other companies carry a full swap kit with everything you need

http://eastcoastgearsupply.com/i-498...er-flange.html

drhoward1988

Just some friendly advice to the OP for a cheaper route; you could swap in a 8.25 rear axle and do the ZJ disc brake swap and have a pretty good rear diff. It's pretty much bolt in and a strong setup, especially if you don't plan on overly large tires in the future. The 8.8 is a good axle don't get me wrong, just another option for ya to think about.

'90Cherokee

I thought about the 8.25 but so many people say it's not worth doing and I didn't know about the brake swap. I think the 8.25 would easily cover my needs, realistically the 35 would but it seems that a cheap & easy brake upgrade isn't available for it. The rear brakes seem weak and it may be because I used a non-ABS proportioning valve, I later found out that the non-ABS XJs had bigger drums. I have grand thoughts of building a bad *** rig, but truthfully I enjoy the challenge of running my 235s and a stock limited slip and finessing obstacles. I do know that when I run across something difficult I want to be able to bump it without worry about breaking an axle. I don't mind cutting & welding the 8.8 and tinkering with brake bias, just didn't know how the driveshaft would work. If it sounds like I'm undecided, I am.

'90Cherokee

With that adapter there's no length issues or any other mods needed to run the D35 driveshaft with an 8.8?

'90Cherokee

Forgot to ask; "pretty much bolt in", what needs to be changed to bolt one in?

drhoward1988

Nothing as far as the axle. The rear disc swap needs some minor mod but no welding or re drilling. Iirc the just need some light honing done to the backing plates

SeriousOffroad

The ZJ disc swap requires re-drilling the backing plates and opening up the hole for the axle tube as well.

Disc brakes from a KJ are a better upgrade.

If you decide to do the 8.8 swap, this makes it a lot easier.
http://www.seriousoffroadproducts.co...y-Ford-8.8-Kit

Fred/N0AZZ

With what you have planned for your XJ you will never break a Chy 8.25 29 spline. I run that with 33x12:50x15's, 4.56 gears and locked 90% of the time off road and plan on going up to 35"'s shortly. Have never broken anything so far.

The 8.25 is a direct bolt in and easy/cheap to find for under $200 at any JY.

EvstaG

IIRC the pinion housing on the 8.8 is almost 2" longer than the D35, you'll likely need to find or make a shorter drive-shaft.