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XJ D44 Buildup


 
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ThePhantum
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PostPosted: Sun Apr 25, 2004 7:27 pm    Post subject: XJ D44 Buildup Reply with quote

OK, so this thread is really part two of the XJ Axle Options thread...but before that one gets too off topic, I figured I would start this one to pose questions/have discussions about the actual buildup.

So you don't have to read the last thread here's a brief synopsis: D44 out of an '87 Cherokee going into a '97 Cherokee. Prior to install it's getting (at least) a ZJ disc brake conversion and alloy axle shafts.

On the alloy shaft front, I've done a little research into them and I've pretty much settled on Superior/Foote shafts, but the problem is their product catalog doesn't list a part number for this particular axle ('87 Cherokee D44). I know the 44 is 30 spline with 1.31" diameter shafts, but what I don't know is the length of the shafts (or if the lengths differ on either side, as they do on TJ D44's).

Anyone know?

Yea...I know...I could wait until I get the old shafts out and measure them, but I'd like to figure this stuff out in advance. Confused

TIA

Steve
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ThePhantum
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PostPosted: Sun Apr 25, 2004 11:51 pm    Post subject: Reply with quote

OK, so I found out that the pass side shaft is 29.75" and the driver's side is 29.25"...making them (seemingly) the same as the shafts for '97 & up TJ's. Part #'s 75186-1x and 75186-2x, respectivley. I'm gonna call them tomorrow to confirm all this of course....

So now the question becomes does anyone have any recomendations on where to buy these things from?
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swamp boy
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Joined: 01 Jan 2004
Location: New Orleans LA.

PostPosted: Mon Apr 26, 2004 5:35 am    Post subject: Reply with quote

I say Superior as well.. I got my axles and gears from them. And I am very happy.. I have broken an axle but they replaced it .. No questions asked.. (It was only 1 month old)

Also are you looking for a new set of ZJ brakes or are you searching the bone yards??
I found mine in a bone yard and rebuilt them.. It cost me $100 for everything at the local yard then rebuilding the drums and calipers was pretty cheap.. I was well under $200 when I was finished... Not to shabby considering what they charge for that conversion kit elsewhere..
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ThePhantum
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PostPosted: Mon Apr 26, 2004 3:44 pm    Post subject: Reply with quote

Yup, I'm going the boneyard route. All I really need is the backing plate, calipers, e-brake shoes and e-brake lever. I'll buy the rotors, pads and brakelines new and I'll rebuild the calipers myself.

Lemme ask ya something Carl, did you do a master cylinder upgrade as well? I'm reading that some people do and some don't, so I'm thinking I might be able to just go with an adjustable proportianal valve to help dial in the brake bias.

edit - Oh yea...where did you buy your shafts from? Direct or through a reseller?

My understanding (on the conversion to an XJ D44 at least) is that the backing plate will require some driling to make it bolt up and the center hole will need to be bored out some. In addition, I'll need a custom spacer made because the ZJ backing plate is thicker than the drum brake backing plate. So, to keep the proper bearing preload the spacer is required...of course all of this is what I'm reading. Once I get the all parts and start test fitting stuff, I'll know for sure.

Rock On!

Steve
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ThePhantum
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PostPosted: Mon May 03, 2004 9:33 pm    Post subject: Reply with quote

Soooo, I took the brakes/backing plates off and pulled the shafts out yesterday (yes...I got lots of pictures, as I will for the rest of the process for the writeup). I ordered the alloys today and I'll be making the rounds at the local boneyards (for ZJ disc brakes) on Friday.

Rock On!

Steve
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ThePhantum
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PostPosted: Mon May 10, 2004 8:01 pm    Post subject: Reply with quote

Got the new axle shafts today.

I'm thinking about going another way with the brake conversion....if I get disc backing plates from a ZJ, I'll have to have them machined so that they will fit the axle tube, as well as have spacers made (to kick the plates out a little) so that everthing lines up. Instead, I'm thinking about just making or having some kind of bracket/adapters made, that would bolt onto the existing drum backing plate and allow the calipers to bolt up. Then I'd just have to fab something up for the e-brake. Overall, I think its the less expensive option.

I need to get rotors and calipers and test fit everything to see just how feasible this little idea is....but any input is welcome.

Rock On!

Steve
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ehirner
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Joined: 01 Jan 2004
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PostPosted: Tue May 11, 2004 1:19 pm    Post subject: Reply with quote

thephantum wrote:
Got the new axle shafts today.

I'm thinking about going another way with the brake conversion....if I get disc backing plates from a ZJ, I'll have to have them machined so that they will fit the axle tube, as well as have spacers made (to kick the plates out a little) so that everthing lines up. Instead, I'm thinking about just making or having some kind of bracket/adapters made, that would bolt onto the existing drum backing plate and allow the calipers to bolt up. Then I'd just have to fab something up for the e-brake. Overall, I think its the less expensive option.

I need to get rotors and calipers and test fit everything to see just how feasible this little idea is....but any input is welcome.

Rock On!

Steve

Ya really think custom parts will be cheaper than readily available parts???
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ThePhantum
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PostPosted: Tue May 11, 2004 9:08 pm    Post subject: Reply with quote

ehirner wrote:
thephantum wrote:
Got the new axle shafts today.

I'm thinking about going another way with the brake conversion....if I get disc backing plates from a ZJ, I'll have to have them machined so that they will fit the axle tube, as well as have spacers made (to kick the plates out a little) so that everthing lines up. Instead, I'm thinking about just making or having some kind of bracket/adapters made, that would bolt onto the existing drum backing plate and allow the calipers to bolt up. Then I'd just have to fab something up for the e-brake. Overall, I think its the less expensive option.

I need to get rotors and calipers and test fit everything to see just how feasible this little idea is....but any input is welcome.

Rock On!

Steve

Ya really think custom parts will be cheaper than readily available parts???


Either way I have to have custom parts made. If I go with the backing plates from a ZJ:

1) I have to have custom spacers made. Because the ZJ backing plate is thicker than the drum brake backing plate, the spacers are needed to keep the proper bearing preload.

2) The ZJ backing plates themselves have to be machined to allow the shaft/bearing/seal assembly to pass through as well as drilled in order to bolt onto the D44 tubes properly. Since some of the bolt holes are "close but not quite", it will also require a little welding to make the holes the correct size to keep the plate from sliding around on the tube.

I'm figuring that the cost (in both time and money) of doing both of these would be equal to or more than just having a couple of brackets made to bolt on to the existing backing plates. It'll be a lot less headache and I'd still be using rotors and calipers from a ZJ, as well as the stock drum backing plate...so it really turns out to be less custom parts in the end.

I dunno, I gotta hit the machine shop and ask them about the costs of making brackets to my specs vs. spacers/backing plate machining to spec.

Stay tuned campers...
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ThePhantum
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PostPosted: Sat May 29, 2004 7:17 am    Post subject: Reply with quote

OK, I'm finally getting ready to do this buildup and I need to make a decision on armor. I've narrowed it down to the following choices (these are in the order I am considering them right now):

Crane diff cover - High clearance, no lips to catch on stuff and seems to be pretty strong.


Warn Diff gaurd - I have one of these on my front diff, which is why I'm considering it for the rear.


Poison Spyder Rockring - Looks pretty meaty and has a good lock on the lip, but seems to have some vulnerabilities to the sides.



I'm leaning towards the Crane, but it is the most expensive option and I don't have any experiance with them. Anybody ever bounce one of them of a few rocks?

TIA

Steve
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97 XJ Sport with a bunch of stuff
Quote:
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ThePhantum
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PostPosted: Sat May 29, 2004 7:48 am    Post subject: Reply with quote

Never mind...after talking to Dan, the Crane cover won't work with his design for the truss. So, I'm gonna go with the Warn.

Saves me a few $$ anyway. thumbs
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97 XJ Sport with a bunch of stuff
Quote:
Never argue with idiots, they drag you down to their level and beat you with experience
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ThePhantum
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PostPosted: Sun May 30, 2004 10:50 am    Post subject: Reply with quote

So, I'm putting this thing together today and in the process of assembly I learn that the wheel mount side (where the lugs are) of the Superior axle shafts are 3/4" wider than the stock shafts. How do I know this, you might ask...


Because the rotors (and thus most likely the calipers) will not fit on the Superiors. So, I'm back to sqaure one researching what rotor/caliper combo will fit. angry angry angry
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