Waggy D44 swap - Pirate4x4.Com : 4x4 and Off-Road Forum
 
Pirate4x4.Com : 4x4 and Off-Road Forum  

Go Back   Pirate4x4.Com : 4x4 and Off-Road Forum > Brand Specific Tech > Jeep - Cherokee
Notices

Reply
 
Share LinkBack Thread Tools Display Modes
Old 02-01-2019, 12:02 PM   #1 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Waggy D44 swap

Figured I'd contribute to this section. Nothing crazy, but it was all built in my garage. I picked up a waggy 44 from CL a couple of years ago and finally got around to finishing the swap recently. There are inherently two issues with using this housing.

1. The bolt pattern needs to be converted to a 5x4.5
2. The housing is setup for leaf springs. The main issue here is the caster angle is negative when setup for the XJ.

My goal was to swap this housing into the XJ using the ruffstuff 3 link heim kit and 1 ton steering. This necessitated building a crossmemeber.

New to me housing
Name:  IMG_4451.jpg
Views: 556
Size:  82.1 KB

Cleaning off factory control arm mounts. The passenger side came off without any tearing of the unibody. The drivers side, not so much...
Name:  IMG_4553.jpg
Views: 537
Size:  52.2 KB

First attempt at building a crossmember
Name:  IMG_4611.jpg
Views: 543
Size:  56.6 KB

Name:  IMG_4627.jpg
Views: 540
Size:  78.1 KB

Welding nuts to the backside of the frame stiffeners. I should have just done all 4 on each side instead of trusting the factory tapped holes, so now I have that issue to deal with.
Name:  IMG_4825.jpg
Views: 557
Size:  67.7 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress

Last edited by GFY Racing; 02-01-2019 at 12:04 PM.
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-01-2019, 12:16 PM   #2 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Mocking up the housing. Spring perches have to be mounted as far out as possible to line up with the springs.

Name:  IMG_5535.jpg
Views: 548
Size:  71.1 KB

Name:  IMG_5536.jpg
Views: 534
Size:  65.4 KB

Name:  IMG_5534.jpg
Views: 538
Size:  72.9 KB

Name:  IMG_5532.jpg
Views: 536
Size:  83.2 KB

MASSIVE 1.25" heims from ruffstuff. Way overkill for a D44.

Name:  IMG_4583.jpg
Views: 526
Size:  61.9 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Sponsored Links
Old 02-01-2019, 12:24 PM   #3 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
After mocking up the housing, it was obvious the inner Cs would have to be turned. Let the good times begin!

Cutting the factory welds. Took quite a while. I don't remember how many disks we went through.

Name:  IMG_5768.jpg
Views: 537
Size:  67.2 KB

Tried using the BFH to remove the Cs. Finally my cousin had a brilliant idea of using some 0.25 plate and the 20 ton HF press. Worked
Name:  IMG_5767.jpg
Views: 529
Size:  56.2 KB

Inner Cs removed.
Name:  IMG_5770.jpg
Views: 530
Size:  58.7 KB

Cs tacked back on to mock it up again.
Name:  IMG_5798.jpg
Views: 525
Size:  79.4 KB

Finished welding the Cs back on. Took 3 or 4 passes if I remember correctly.
Name:  IMG_5840.jpg
Views: 543
Size:  73.0 KB

Caster ended up right around 5.5-6 degrees.
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
 
Old 02-01-2019, 12:33 PM   #4 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
While I was working on getting the axle ready for the XJ, I decided to use the kit from ECGS to convert the axle to 5x4.5. The kit is complete and includes everything from the spindles out, not including the hubs.

I was working upstairs when I heard the fedex truck pull up. The driver apparently wasn't having a good day and droped the box at the front door. By the time I made it downstairs he was already gone. This is what I was left with.

Name:  IMG_5178.jpg
Views: 547
Size:  97.6 KB

Name:  IMG_5182.jpg
Views: 537
Size:  63.9 KB

Name:  IMG_5184.jpg
Views: 525
Size:  52.8 KB

I got on the phone right away with ECGS. Those guys have badass customer service. They sent out another order the same day.

Once the new, unfucked, parts came in I was able to get the axle mocked up with the tires.

Name:  IMG_5844.jpg
Views: 536
Size:  62.0 KB

Name:  IMG_5846.jpg
Views: 527
Size:  59.2 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-01-2019, 12:37 PM   #5 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
More mockup pictures.

Name:  IMG_5863.jpg
Views: 521
Size:  62.1 KB

Name:  IMG_5865.jpg
Views: 525
Size:  63.0 KB

Name:  IMG_5868.jpg
Views: 532
Size:  65.8 KB

Name:  IMG_5884.jpg
Views: 525
Size:  79.4 KB

Name:  IMG_5890.jpg
Views: 518
Size:  80.9 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-01-2019, 08:46 PM   #6 (permalink)
Registered User
 
Join Date: Sep 2005
Member # 53453
Location: On the Bottle
Posts: 22,552
Too bad you're so far away, I've got a set of Yukon 4340 shafts and Superjoints for that axle, and I'd damn near give them to you, because I'm never going to use them.
__________________
Quote:
Problem with truffle butter is that it isnt gay st all

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
DirtyComanche is offline   Reply With Quote Quick reply to this message
Old 02-02-2019, 05:47 AM   #7 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Waggy D44 swap

How much would shipping be to Leander TX?


Sent from my iPhone using Tapatalk
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress

Last edited by GFY Racing; 02-02-2019 at 06:18 AM.
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-02-2019, 06:41 AM   #8 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Decided to rework the crossmember. Ended up cutting off the mounting plates on the sides. Instead of flush mounting with the crossmember, I notched the crossmember about 1/3 of the way down at a slight angle.

Name:  IMG_5886.jpg
Views: 501
Size:  79.5 KB

I notched the control arm mounts to give another inch of clearance. Because the heims are so large, I ended up notching the crossmember as well. Turned out better than I expected. Nevermind the shitty tack welds.

Name:  IMG_5887.jpg
Views: 505
Size:  64.3 KB

Name:  IMG_5888.jpg
Views: 492
Size:  57.9 KB

Nearly finished aside from paint and the plate for the upper control arm mount. Between notching the transmission mount and the lower control arm mounts, I gained 2" of clearance for the lower arms.

Name:  IMG_6098a.jpg
Views: 503
Size:  55.6 KB

Random shot of the tierod. I used ruffstuff's y-link kit and flipped the tierod. Instead of re-reaming the taper, I used their tapered inserts and drilled the knuckles out. The knuckles are drilled out to 7/8". I borrowed a buddies 1/2" corded drill and easily drilled them out. None of this "oh boo hoo, I nearly broke my arm when the bit caught" that others love to whine about.

Name:  IMG_6120.jpg
Views: 496
Size:  62.5 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-02-2019, 06:47 AM   #9 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Final flex shots. Currently there 10" of travel before the springs start to drop out. I'm hoping to find some dual rate TJ springs to use to give some more droop eventually, but it's not a priority right now. For the time being I'll just run some limit straps.

Name:  IMG_6440.jpg
Views: 486
Size:  78.8 KB

Not much flex in the rear currently. I'm running brand new 3.5" RE springs with their 1" shackle, so with some more weight and breaking them in they should do a bit better.

Name:  IMG_6441.jpg
Views: 490
Size:  83.0 KB

Name:  IMG_6444.jpg
Views: 513
Size:  67.4 KB

This is the most recent picture of the front end. As it sits now, both the drag link and track bar are parallel.
Name:  IMG_6446.jpg
Views: 509
Size:  86.5 KB

More trimming is needed.

Name:  IMG_6447.jpg
Views: 511
Size:  60.9 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress

Last edited by GFY Racing; 02-02-2019 at 06:49 AM.
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-11-2019, 08:09 AM   #10 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
One issue I'm running into is turning radius. I had to mount the driver side link a little further out due to interference with the housing. As a result, the tire contacts the link before hitting the steering stop. I've temporarily addressed this by using a longer bolt until I have time to come up with a better solution.

Driver side at full lock

Name:  image1(2).jpg
Views: 431
Size:  54.3 KB

Passenger side at full lock

Name:  image2.jpg
Views: 428
Size:  46.6 KB

Interestingly the passenger side is hitting the internal stering stop before the stop on the knuckle or hitting the link, giving me less turning radius when making left hand turns.
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-13-2019, 10:35 AM   #11 (permalink)
Registered User
 
Join Date: Feb 2011
Member # 183091
Location: Livingston tx
Posts: 163
I’m curious to see what you think of the RE 3.5” springs. I’ve been thinking of getting some of those with a 2” shackle.
__________________
89 XJ
Whitesnake is offline   Reply With Quote Quick reply to this message
Old 02-13-2019, 01:36 PM   #12 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
I've only put about 50 miles on them so far, none of which are offroad. I'll report back when I get a chance. But that being said, no complaints aside from the obvious lack of flex. I'm hoping that will get a bit better as they break in.
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-13-2019, 01:43 PM   #13 (permalink)
Pirate4x4 Addict!
 
the freeak's Avatar
 
Join Date: Jan 2005
Member # 41185
Location: In the garage
Posts: 5,116
Quote:
Originally Posted by GFY Racing View Post
One issue I'm running into is turning radius. I had to mount the driver side link a little further out due to interference with the housing. As a result, the tire contacts the link before hitting the steering stop. I've temporarily addressed this by using a longer bolt until I have time to come up with a better solution.

Driver side at full lock

Attachment 2919382

Passenger side at full lock

Attachment 2919384

Interestingly the passenger side is hitting the internal stering stop before the stop on the knuckle or hitting the link, giving me less turning radius when making left hand turns.
Is your pitman arm centered when the steering box is centered?

If not, center it, and you'll probably need a longer drag link, and a longer (eye to eye) pitman to accommodate the new steering geometry.

EDIT- you can file out the "keys" on the pitman arm to allow clocking it on the sector shaft.

Here's a link you may find helpful: https://www.pirate4x4.com/forum/gene...reference.html
__________________

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

RIP SCREWZER2
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Last edited by the freeak; 02-13-2019 at 01:47 PM.
the freeak is offline   Reply With Quote Quick reply to this message
Old 02-13-2019, 01:47 PM   #14 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
I know it SHOULD be, but won't hurt to double check. Thanks for the input.
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-13-2019, 02:02 PM   #15 (permalink)
Rock God
 
whitneyj's Avatar
 
Join Date: May 2009
Member # 135947
Location: Oshkosh, WI
Posts: 2,376
The rear will flex a lot better if you were able to move the shackle to a better angle. I had a very similar setup in 2009 and ended up cutting out the factory rear shackle box and building my own that moved the shackle bolt forward. Made all the difference in the world. I know there are companies that offer bolt on shackle relocation kits as well, but that's not as fun

Swap looks good.
__________________
Place banana in your ear.
Observe that there are no alligators around.
Conclude bananas placed in ears keep alligators away.
whitneyj is offline   Reply With Quote Quick reply to this message
Old 02-13-2019, 02:37 PM   #16 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Thanks man. I'm hoping to address that in the next few months. Right now I've got way to many projects going on so it'll have to suffice. I'm sure I'll find some time this summer when it's hot enough to make working on it painful
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 02-27-2019, 10:09 AM   #17 (permalink)
Registered User
 
Join Date: Feb 2015
Member # 548137
Location: E Texas
Posts: 89
looks like you pushed the axle forward about 2 inches but used centered spring mounts. your coils bowed at all?
denverd1 is offline   Reply With Quote Quick reply to this message
Old 03-01-2019, 08:24 PM   #18 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Quote:
Originally Posted by denverd1 View Post
looks like you pushed the axle forward about 2 inches but used centered spring mounts. your coils bowed at all?
No, the coils are as straight as they were before the axle swap.
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 03-01-2019, 11:49 PM   #19 (permalink)
Registered User
 
Join Date: Feb 2015
Member # 548137
Location: E Texas
Posts: 89
Quote:
Originally Posted by GFY Racing View Post
No, the coils are as straight as they were before the axle swap.
What tire size bro? 37?

Sent from my SAMSUNG-SM-G930A using Tapatalk
denverd1 is offline   Reply With Quote Quick reply to this message
Old 03-02-2019, 08:37 AM   #20 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
35s

Unfortunately itís going to be a bit before I can actually wheel it. The motor has developed a knock so the oil pan is getting dropped this weekend


Sent from my iPhone using Tapatalk
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 03-15-2019, 04:17 AM   #21 (permalink)
Registered User
 
Join Date: Jan 2019
Member # 863064
Posts: 37
You Have any more updates on your project?
Boogs1970 is offline   Reply With Quote Quick reply to this message
Old 04-01-2019, 05:19 AM   #22 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Not on the D44. It's sidelined due to a small hicup in the engine break in. This is 75 miles into it. I'll be updating my other thread in non hardcore.

Name:  rod bearings.jpg
Views: 164
Size:  92.5 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress

Last edited by GFY Racing; 04-01-2019 at 05:20 AM.
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 04-01-2019, 10:32 AM   #23 (permalink)
Get Off My Lawn
 
Action Fab's Avatar
 
Join Date: Aug 2006
Member # 77386
Location: Little Rock, AR
Posts: 13,012
Blog Entries: 1
Eeek. What are you thinking caused the premature wear?
Action Fab is offline   Reply With Quote Quick reply to this message
Old 04-01-2019, 10:35 AM   #24 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
Quote:
Originally Posted by Action Fab View Post
Eeek. What are you thinking caused the premature wear?
Best guess is oil starvation. I haven't torn it apart anymore than this, and really don't plan to. Looking into other power options at this point.
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Old 04-03-2019, 07:42 PM   #25 (permalink)
Zeus of the Sluice
 
GFY Racing's Avatar
 
Join Date: May 2009
Member # 136091
Location: Back in the good 'ol U S of A after three long deployements!
Posts: 2,882
For anyone interested in the motor fiasco, I picked up an LQ4 from an 05 H2 that will be here in a week or so. I'll be updating my build thread in the non-hardcore section.

Name:  LQ4.JPG
Views: 172
Size:  33.4 KB
__________________
Fighting for the right for SORRY PIECES OF SHIT to protest at soldier's funerals.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1989 XJ on 35s Work in Progress
GFY Racing is offline   Reply With Quote Quick reply to this message
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Pirate4x4.Com : 4x4 and Off-Road Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.

** A VERIFICATION EMAIL IS SENT TO THIS ADDRESS TO COMPLETE REGISTRATION!! **

Email Address:
Insurance
Please select your insurance company (Optional)

Log-in


Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Ultimate Wrangler Build Ups and Swaps thread gtxracer Jeep - Hardcore Tech 364 09-28-2017 04:54 AM
Barnes 4WD Solid Axle Swap Kits Barnes 4wd Suspension 46 05-02-2017 06:05 PM
79 waggy D44 front into a 86cj7 steering questions CutterN55 Jeep - Non Hardcore 2 03-17-2014 10:55 PM
Front d44 from a waggy into a ZJ Riot1987 Jeep - Cherokee 11 12-06-2013 06:26 AM
Waggy D44 Ball Joint Issue - Camber Sleeve CaddMan Jeep - Non Hardcore 0 03-23-2012 02:22 PM


All times are GMT -7. The time now is 07:53 PM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.0 ©2011, Crawlability, Inc.
User Alert System provided by Advanced User Tagging (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.