High Quality - Heavy Duty - Hard Core

Ford 8.8 Axle Install: Jeep TJ

Erik's Axle Preparation

Erik, searching long and hard, procured the donor axle from a local wrecker with the right gear ratio (3.73:1) and factory TrackLoc posi carrier. What he ended up with was an axle out of a 1995 Ford Explorer Eddie Bauer – 3.73L complete WMS to WMS.

Once home Erik drained the fluids, and remove the WMS for cleaning, inspected, sold the TrackLoc, removed the existing brackets and grinded everything smooth.

Erik purchased a TeraFlex bracket kit, 8.8 master install kit, set of upper and lower adjustable superflex control arms from Rubicon Express, the companion flange, and an Auburn ECTED electric locker. Next stop 4x4Beast Fabrication!


What The Beast Did

Erik shows up early on Saturday morning with his axle in tow and a box of donuts to soothe the savage Beast. Rockalot & Sleepy are also in attendance to aid in menial tasks such as sanding, grinding and parts/food runs.

The TeraFlex brackets are cut for a D44 with 3” tubes, the 8.8 has 3¼” tubes, so we did need to do a little grinding to get them to lay on the axle nicely. Once cleaned, we first stick welded the tubes into the housing using proper techniques to insure that we didn't change the dynamics of the steel tubes & cast-iron housing which included: pre-heating, welding .75" at a time using a total of five 275 stainless sticks per side, 30 min. post-heating.

Next part was much easier but still needed to be precise. Big John and the rest of the crew took thorough measurements for placement of all the brackets and double checked against Erik's Jeep. Confident in our measurements, Big John welded everything into place.

By mid afternoon Erik's axle was ready to be loaded up and taken to West Coast Differential to have them install the new bearings, seals and wire up the ECTED!

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