Hey guys. I took one welding class my senior year of high school at the local college. I took an arc welding class. That being said, it was only a 9 week course, and I learned a little bit, but not real advanced. That was a few years ago. I have bought a torch and a Hobart 140 mig with .030 wire. I have been trying to decide if I want to regear, or buy a ford 8.8 out of an exploder and swap in with 4.10's and find a matching d30 front with 4.10's. I was curious if my 140 would penetrate enough to weld the brackets on?

You'd be right on the borderline, I personally would use a 220 machine to do it.. Don't really want stuff on your axles failing.

Pretty sure the 140 burns hot enough to weld 1/4" in a single pass. I think it would be plenty strong.
I have the Hobart 190, that thing is a beast for its size.

That being said, practice, practice, practice before you even think about welding on there. Don't want to be cutting and re-welding over and over.

I wouldn't do the swap to begin with the Chy. 8.25 29 spline is quite strong for up to 35" tires and your 99 has that one unless your planning on HD Rock Crawling or the like. If disc brakes are only reason for the swap just add them to the 8.25. I would re-gear and did on my own "99" D30/8.25 to lockers and 4.56 gears, wish I had went with 4.88's as I now run both 33's and 35" tires.


You say your after a 4.10 gear so I guess you plan on running nothing larger than a 31" tire ever on your XJ so that will bring you back to stock gearing.

Fred, you are the voice of reason again. I completely looked over the whole point of his swap. I guess I just got excited when I saw a welding project....

OP, Fred is 100% correct. Unless you want to go bigger than 33 or 35's, there is no need for an 8.8. You may he able to find another 8.25 out of a 4 cylinder that has 4.10's already in it, or just regear yours for a larger tire. Not a lot to be gained for all of the work.

I just figured that it would probably be easier to find one with 4.10s and swap it as well as the front...I can't find any rear's with 4.10s within 200 miles...Ahh well, looks like I will probably just buy gears and attempt it.