The Foxtrot Mafia Build

[Irun]

I would also not drop a Chrysler 8.25 in there. Better off with a Super 35. Finally - the strength difference between a super 35 and a 44 is not much, so it's definitely an appropriate solution - especially if you can't find a 44 for a decent deal.

The OP's plan to do a super 35 is solid. Great strength for 35's, 0 fabrication to install it, and building the super 35 is not a huge task.

Most folks don't think about the small amount of ground clearance advantage, at the housing, the Super 35 has (Approximately 1/2"), the modest weight advantage (30 - 50 lbs), and the 1" longer difference in the Dana 44 housing. To put the 1/2 of clearance in perspective, that means you'd need to go up 1" in tire size to be comparable.

 

[Dan The Video Man]

Such a fun week working on the TJ! Got the axle DS UCA bushing installed. I need to bring the uppers back some for more positive caster, should've left good enough alone. I think it was 8.5º on the DS, I took it to about 7.4º and the TJ does not like it. Oh well, east fix that I'll get too soon enough after I help my buddy with his stupid Prius and then try to track down where my wife's Ranger is leaking fuel, Unless someone decided to go into my garage and pour some gas on the floor underneath it...

After that, I had to take care of this seized body mount bolt that broke off. I've extracted many bolts over the years from all over different vehicles and I can honestly say this one was the biggest pain in my ass I've had. A lot of folks here provided suggestions to get it out and I want to thank everyone that did. After some patience and a bit of elbow grease, it came out with no damaged threads.

It was important to get this out because I had a BL and MML lift to install. I went with the Teraflex 1" aluminum BL and the Zone 1" MML. I was able to get both for under $150 from 4WP.

This was my first time installing a BL since my previous TJ already had one installed. Pretty straight forward, only a couple of the bolts weren't lining up perfectly. A little grunt work with crowbar took care of it rather easily.

Now I've got a bit more clearance which will definitely come in handy when I make the move to 35s!

 

[Dan The Video Man]

Super stoked! Just put my order in with TW for my DC rear DS. Rear adjustable uppers are on their way and should be ready to install this SS SYE next weekend!!

 

[Dan The Video Man]

I had been sitting on my JB conversion SS SYE for a while as I saved up the funds for a DC DS and adjustable rear UCAs and the moment had finally arrived!

I started working on it yesterday after work, the plan was to have the TC out, split and the SYE installed before bed allowing the RTV to cure overnight. That was a success. I even cleaned up the case as best I could with the time I allowed myself. As you can see from the spots I didn't get so well, it was filthy all over.

This morning, my plan was mount the case, install the new DS and fine tune the Savvy cable shifter I installed a few weeks back. By the time all that was done, my UCAs should be close to arriving.

Everything went smooth up until the UCA delivery part of the plan...

Welp, so much for getting my pinion angle dialed in. Of course, this ruined my plan of having this finished by the time I have to go into the office tomorrow morning. I guess I'll have to wait until tomorrow. Either way, it looks daaaaamn good if I do say so myself!

 

[Dan The Video Man]

Well, that was easy! Driveshaft is 15.1° and pinion is 14.9°. I’ll see how it feels on the drive to work tomorrow.

 

[Dan The Video Man]

Ride was smooth as hell to and from work yesterday but didn't like the idea of my pinion angle being slightly higher than my DS (even though it was only .2º), so I brought my UCAs in just a smidge. 14.1º on my pinion angle and 14.8º on my DS angle.

Unfortunately during this process I ended up snapping one of the UCA bolts at the frame side. I guess I tightened it too much before I went to torque it down, wasn't getting the click and POP, snapped. Luckily the old bolts were still in really good shape so I just used one of those.

Then I went to get the front pinion angle dialed in. It was around 5º on the pinion and 9º on the DS. I adjusted pretty good, took it out on a test drive up the side streets then back down the highway to get home. 75mph and smooooooth with no vibes at all! Of course upon rechecking this morning, my front pinion angle is a little higher then my DS angle. I figure pulling in the UCAs either a half turn or full turn should get me square.