Vacuum Disconnect + Trail updates

[Sly8795]

I have a 1990 Cherokee and my 4 wheel drive failed last winter. The shift fork let go. Its works since then. I'm trying to get my rig in trail ready condition so I can go out with my freind whos got a really beefed up 91 explorer. He'll probably have to pull me through some spots till I get everything done but anyways on to my question. I found the write up of how to create the manual disconnect and bought all the stuff i thought i needed. But upon doing this it appeared that the spring mentioned in the write up is to big. Has anyone done the manual disconnect on a 90? The spring sized mentioned was 2.75 - 1/2. Instead of a brake cable I bought a truck choke cable.

To fix the problem temporarily and for cheap we took a hose clamp and put the colar into the connected postion so the axleshaft is always connected. Has any tried this before as well? We tested it and it seems to work.

Also I think ive read that I can get axle shafts from a 95+ tj so I get the bigger shafts and u-joints is this true?

My freind also gave me an 8.8, Ive found a few writeups on this and it looks like a good setup. Does anyone have suggestions on gearing so its driveable but has enough to go through the trails? I plan on installing lockers front and rear. Most likley lunchbox lockers but if i have the money id like to get selectable lockers

What up chain hook up methods i.e. some sort of front hooks incase i do get stuck and need a tow?

I hope this will be an ongoing post with some advice on upgrading my jeep for good trail truck...if this has been created elsewhere a link would be appreciated.

Thanks

 

[Bounty__Hunter]

You can take the disconnect housing off the axle, flip it upside down, and reinstall it. It will then hold the shift collar in the locked position.

You can switch to '95 YJ axleshafts for the larger ujoint while retaining the disconnect. You can go to TJ axleshafts to get rid of the disconnect, but there's a special axle seal that will need installed.

Gear ratio depends on engine size, transmission type, tire size, type of wheelin, etc. Hard to give you a recommendation there without more info.

You had get on the ball with the mods, we don't want to hear about that Exploder pulling you anywhere :shock:

 

[Evan]

This is the Explorer that would be pulling him:

1991 Explorer Sport 2dr
5.13 gears, lockers
Transfer case doubler, both cases manual, final crawl of 117:1
M5OD 5-speed transmission
31-spline 8.8 rear with discs
Dana 35 hi-pinion front with 760x joints, F-150 coils and shocks, manual hubs
Rebuilt 4.0L V6 Cologne OHV engine
Aluminum fuel cell, wiper cowl intake, 1350 driveshafts, OBA
35x12.5 ProComp MudTerrains on 10" RockCrawler rims
5.5" lift, trimmed fenders
Moog balljoints and TREs

It is however, NOT trail rated.

So the plan is that he will be getting my old 8.8 with a set of 4.56s and discs, some 95+ shafts up front, and my old 33" Swampers.

 

[Sly8795]

As you can see my buddy posted his rig.

I was wondering what type of seal is need for the TJ upgrade also is it a specific year of axle shaft I should look for and a good place to find used ones? Is there a write up somewhere

Also I was wondering what the common process was to add some tow hooks to the front of the jeep cherokee?

As far as gearing I have the 4.0L currently running 31's with an automatic. And as far as wheeling anywhere the trail takes me i suppose. Mainly trail riding and I would be driving to the trails as well.

 

[Bounty__Hunter]

The stock 3.55 gears do pretty well with 31" tires.

As for the front tow hooks, I think the best option is a front drawtite receiver. They're rated at 9000lbs, cost a little over $100, and really tie the front psuedo-framerails together. Any other towhook bracket really sucks at any angle besides straight on.

 

[Sly8795]

Thanks for the idea of the front hitch, I was able to find one for 88 bucks.

My next question would be to upgrade the axle shafts or just get the stronger spicer ujoints? If i go with the spicer u joint does anyone know if 5-260x is the correct part?

If I upgrade the axles to the TJ is there a good place to look? I've done breif searches on the net but haven't come across anything.

 

[Bounty__Hunter]

The 260x is the smaller weaker ujoing, the 297x is the larger stronger ujoint found on '95 jeeps and D44 front axles.