Switching the D35 for a 8.25 Rearend

[flash2pablo]

I have a few questions about this swap.

First off is it a direct swap?

If not what kind of other work would need to be done to make a swap like this work?

The reason i ask is that I had a 96 Cherokee that had ABS and the D35. I sold it because I want a stronger Rear axle. But all I can find for a new jeep, are with D35's. So I am thinking if its not too much work just doing a swap. I am planning on building my first decent dd/weekend warrior.

I am probably considered a noobie, with the info i know about mechanics, But i really am trying to learn and I am planning on doing all the work myself, probably with the help of a friend or two.

Thanks for all the helpful info!!!

PBen

[90XJay]

It is a direct swap HOWEVER make sure you are matching the same gearing! don't ever mix an axle with lets say 3.07's in the front but then put an axle with 3.55's in the rear. Make sure the gearing iss the same and it shouldn't be a problem. I swapped my 90xj's 30/35 for a 30/8.25 out a 98 and had no problems at all.

[CanMan]

E brake cables may be different lengths, it was when I swapped in a 97+ Cryco in my 91. But, the D35 and 8.25 brakes are the same, so use the D35 E brake cables on the 8.25. Also, you will need new U bolts. Get new ones, not used. The top retaining plate on the leaf spring will work from the D35, the holes are slutted. Thats the only problems I ran into.

[JeffsJeep04]

...the holes are slutted...

Does that mean they are loose? :laugh:

[xjtrailrider]

Not to hijack or anything but I was just wondering(without going out to the storage building and looking at my old D-35's and 8.25's). Are the backing plates the same? If they are, you could just pull the axles and unbolt the backing plates and brake lines and set the assemblies aside and install the axle housing and then just reassemble everything without even having to remove the "E" brake cables or take the brake shoes/springs/wheel cylinder out.

This will only work if the backing plates are the same though.

Just wondering!

[RCP Phx]

One thing not mentioned yet,the late D35 is a ABS axle,the 8.25 is non-ABS.

[ILLXJ]

Make sure you get the drive shaft from the donor. They are different lenghts. JIM.

[stewie]

I swaped ou my 35 for an 8.25 out of a 2001 right before the fall fling. it IS a direct swap. my donor had no e-brake cables so i used the ones that were on the jeep already. they worked great even at full flex on Gold Bar and PSM. the drive shafts are different lengths on vehicles equipped with a 35 vs 8.25, however with a lifted xj, that problem gets negated. but i am not running an sye, so i cant say how it would work with that. as far as the ABS goes, i just yanked the maxi fuse and the relays under the hood. i still have the ABS light glowing but ill just take the light out of the dash next time i open it up.

things to watch out for;
gear ratios
axle seal condition
do the brakes need replacing
NEW u-bolts

[flash2pablo]

Somewhere i saw a picture of both a D35 and a Chrysler 8.25 side to side. Does anyone know where it might be at?

[CanMan]

Somewhere i saw a picture of both a D35 and a Chrysler 8.25 side to side. Does anyone know where it might be at?

Trying to tell them apart? The 8.25 will have 3" tubes, as where the D35 will have smaller ones. The 8.25 has a flat lip across the bottom, as where the D35 is rounded.

http://www.coloradok5.com/axleguide.shtml

Look at the D35 pic. The 8.25 looks like the 9.25 near the bottom.