so, another "Variation" of the list
8.8 welded up for an XJ
4.88 gears
spool? or Lunchbox? (cant afford a full or selectable locker)
Diff cover (heard 8.8 covers are paper thin)
Dana 30
4.88 gears
aussie'd
alloy shafts
What am i looking at with cost?
Here’s what I would do.
-Rear-
$400 Find an 8.8 with good 410's and brakes and buy it. (realistic in Lynnwood)
My gears were in good shape but the bearings we're on their way out so maybe factor $100 for a master install kit and fluid if required. Obviously fluid is required you freakin trolls.
$40 for good Spring perches (RE). Relocate your stock shock mounts.
$300 w shipping for Lunchbox locker
-Front-
$190 4.10 Yukon Gears for the D30 (Ebay )
$100 Master install Kit
$300 Lunchbox locker
$25 197 shafts from pull-a-part
I have no idea about the labor cost.
I believe you’re dreaming on the 29spline 8.25 axle 3.55 gears Aussie locked (125+280).
-suspension-
I have radius arm (TNT) and would go with three or more links if I had to do it again. I've had no problems but it would be nice not to have the inherent unloading. As you know traction is hard to find here in the NW. In my case the unloading is the most traction inhibiting factor for my xj as a whole. My TNT skid plate is very nice but the money would have been better spent on drop brackets, top-shelf shocks and links.
$200 Drop Brackets
$??? Control Arms (since yours are solid)
$750 33" Tires
$200 Rubicon express SYE with front driveline for the rear *already have spare front shaft*
$200 Diff covers (brand?)
$300 Warn M8000 winch *uncle builds them*
$285 + shipping
DIY winch bumper
$185 + shipping
DIY non-winch bumper
http://stores.shop.ebay.com/Iron-Scorpion-LLC__W0QQ_armrsZ1
$450 Lincoln 180HD
$100 Argon CO2 bottle
$40 HF auto-dimming helmet
HF 4.5” angle grinder, cutoff discs, grinding discs
$100 Make your own slider materials
Total (minus control arms, and bumpers) $3795
If you really want to have a good time here’s all the tools I used to set up the axles.
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=95853 (seal driver)
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=40966 (Puller Kit)
This:
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=37824
+ 16” of fine-thread all-thread, grade 8 hardware, and this :
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=3979
gives you the ability to pull pinion and carrier bearings without a press. A press is nice though.
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=623 (dial indicator)
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=5645 (magnetic Base)
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=895 (micrometer)
Memories of showing you kids how to fix your own car = priceless