8.8 Project
To get the brake hoses to point in the proper direction the blocks where precision eyeballed and milled to allow them to be re-indexed.
With a completed brake system and a extra hand from
@scribzilla we maneuvered the axle in place.
This is where the photos stop, for the most part.
While doing the 8.8 Swap i went ahead and sprung for a set of Metal Cloak fully adjustable control arms, This made lining up the holes, centering the axle much easier, and bracket to axle alignment less critical. We pushed the axle just past center to the rear and the driveshaft, trackbar, diff cover etc clear without any issues. This only left two problem areas, Swaybar and Brake lines. The Shocks ran into the junction points from the brake lines (who saw that coming?) and the Swaybar hit the top of the center section where they have a case protector for the ABS sensor. The center section just needs some clearancing to allow the swaybar to fit over it. The brakes would take some rework. This is what i came up with (no photos)
Brake line modifications rev. 1.1 - MS Paint style.
I ended up useing a 12 inch hard line, cut down and formed to about 10 inches on the driver side, and a 40 inch cut down to about 30 on the passenger side.
The brakes pads i ordered from rock auto were wrong. Apparently there are 2 different sizes used on the explorer 8.8, a small and large size pad. Mine uses the larger 2002 sized brake pad.
Running JK Rubicon wheels, the 1.25 wheel adapter from the 35 was wide enough however a 2 inch spacer is really needed. Those have been ordered from
https://wheeladaptersusa.com/
I got lucky to find a Limited Slip 3.73 Geared axle, So it matches the front i have a used SOLID differ cover to be installed once i repair the stripped Drain Plug. It will get a fluid change when the new cover goes on.
That about sums it up. Drove it home Sunday night. Id say this was a weekend project, never really got in a hurry We stretched it over 3 days but could have easily been completed in 2 solid days.
To Do
Parking Brakes
Sway Bar
Change Cheese Grade Pinion Bolts
Locktite New Wheel Adapters
Diff cover
Fluid Change