JPOR: XJ axle swap observations - LONG

[Jeff <jayers@xxxxxxxxxxxxxx>]

Hey all, Just thought I would share me recent junk yard search results. 
I am looking into building my own High Pinion D44 front end for my '92
Cherokee.  My original plan was to use a mid 70's Ford front housing and
shorten it to accept mid 80's Grand Wagoneer axle shafts with Chevy
knuckles (set up for high clearance steering).  This should make the
wheel mounting surface to wheel mounting surface the same as the Grand
Wagoneer axle yet have a high pinion center section.  I would either use
Grand Wagoneer parts from the Knuckle out (6 on 5.5 bolt pattern) or
Chevy parts from the knuckle out (also 6 on 5.5 bolt pattern and I think
pretty much the same parts as the Grand Wagoneer) or if I wanted 5 on
5.5 bolt pattern I would use Ford hubs and misc parts to complete the
housing.  I am pretty sure all these knuckle out pieces would end up at
the width.  So, I did quite a bit of junk yard searching and
measureing.  Here are my results:

Grand Wagoneer front axle -
width - 60 3/4"
drivers side wheel mounting flange to center of pinion - 21 3/8"
passengers side wheel mounting flange to center of pinion - 39 1/2"

Stock '92 Cherokee front axle (two composite rotors)
width - 60 1/2
drivers side wheel mounting flange to center of pinion - 21 3/4" 	
passengers side wheel mounting flange to center of pinion - 38 13/16"

Junk yard Cherokee front axle (solid rotors)
width - 60 1/2"
drivers side wheel mounting flange to center of pinion - 21 5/8"
passengers side wheel mounting flange to center of pinion - 38 7/8"

So, the Grand Wagoneer drivers side is 1/4" to 3/8" shorter than the
stock axle, the passengers side is 11/16" to 3/4" longer than the stock
axle, and the total Grand Wagoneer axle width is 1/4" wider than the
stock axle.

Based on this inf., a Grand Wagoneer front D44 axle is very close in
dimensions to the stock Cherokee RC D30 dimensions.  It is slightly
wider and the pinion is offset a slight bit further to the drivers side
which will actually help clearance between the diff and the exhaust.

I also thought I would swap in a Grand Wagoneer D44 rear to match the
new front as far as width and bolt pattern.  Here are my measurements of
the rear axles.

Grand Wagoneer rear D44 - no drums
width - 58 1/2" 
drivers side wheel mounting flange to center of pinion - 29 1/4"
passengers side wheel mounting flange to center of pinion - 29 1/4"

Stock "87 Cherokee rear D44 with Moser custom shafts
width - 60 1/4" 
drivers side wheel mounting flange to center of pinion - 30 3/4"
passengers side wheel mounting flange to center of pinion - 29 3/8"

Stock junk yard D35 rear axle
width - 60 1/4"
drivers side wheel mounting flange to center of pinion - 30 7/8"
passengers side wheel mounting flange to center of pinion - 29 3/8"

So, the Grand Wagoneer rear D44 is 1 3/4" narrower than a stock axle
with the pinion is offset 3/4" further towards the drivers side than a
stock axle.  The Grand Wagoneer rear axle is also about 2" narrower than
the Grand Wagoneer front axle when figuring on 1/8" thick brake drums. 
The spring pads are already set up for spring over and are the same 43
1/2" apart as the stock xj axle.  

I don't think the pinion offset would cause much of a problem and the
different widths between front and rear are apparently not uncommon on
vehicles.  However, I think the front of my cherokee's body is already
narrower than the rear and the tires already look like they stick out
further in the front than the rear.  So, I really don't want the rear
end to be 2" narrower than the front.

I could build the front as outlined and end up being perhaps 1/4" wider
than stock at the wheel mounting surfaces.  Then I could use my current
stock D44 rear end (real close to the width of the custom front end when
you add in the 3/8" or so of the rear disks) and change wheel bolt
pattern on the axleshafts by dual drilling the flanges (if there is
enough flange diameter) or selling these axle shafts and having Moser
make another set with the correct axle flange.  But, in order to
maintain the wheel placement that I want, I would need to use 15 x 8
4.5" backspaced wheels with the stock axles.  That same backspacing
would then also need to be used with the custom front axle and stock
rear axle (with bolt pattern change.)  I would like to be able to use
stock Grand Wagoneer rims or stock Chevy rims for their cheapness and
availability, but I think they are more like 3.5" backspacing.  

Another possibility I am pursueing is to use the Grand Wagoneer D44 in
the rear of my XJ with 3.5" backspaced rims.  This would place the tires
just about the same as the previous setup using 4.5" backspaced rims. 
However, what to do to the front to get it 2" narrower so I can use 3.5"
backspaced rims (wich will also keep the lockouts covered better)?  If
there are enough splines and enough seal area on the front GW
axleshafts, I could build the housing in such a manner as to place the
shafts 1" further in the diff.  I may have to cut off an inch of the
shaft, but I believe that would work.  Custom shafts or shafts 1"
shorter from somthing else would also work.  Lots of thoughts without
spending anything so far!!  Feel free to comment on anything.  Jeff