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In January 2005 I began the process of doing the gears and lockers. Even though the 7" lift articulates like there's no tomorrow allowing all four tires to almost always remain on the ground, occasionally a slick spot would trip up the open differentials and I would sit there with tires spinning and no power going to the ones that have traction. Since there are no aftermarket lockers for the Grand Cherokee Dana 44 (made with ALUMINUM, what was Jeep thinking?!), I started to look for a different axle. After a fair amount of research, I settled on the Ford 8.8. For whatever reason, the junkyards in Denver did not have an 8.8 with disk brakes for under $500, so I went to the Internet. I finally acquired one from a 2000 Explorer (never used) on eBay.

There are numerous lockers available for the 8.8 (this being one of the reasons the 8.8 axle is so popular amoung off-roaders). Eventually I settled on the Auburn ECTED. The unique design of the ECTED allows it to function as a limited slip when off, and as a full locker when engaged. Since my ZJ is also a daily driver, I like the notion of having the LSD for driving in snow and icy conditions in addition to being able to lock it up on the trail.



Up until this project, I was driving around with the same 3.73 stock gears I had before lifting the ZJ and putting on larger tires. With the 35x12.5's that I'm running, I was definitely sluggish when starting from a full stop. Even in 4-low on the trail I had a tough time going up some of the steeper hills and obstacles. So it was not a moment too soon that I put in some 4.88 Yukon gears from Randy's Ring & Pinion. They've made a huge difference, and I actually spin the tires at traffic lights now if I give it too much gas!

For the front, I took out the open differential Dana 30 and put in a much stronger Dana 30 HP (high pinion) from a '91 Cherokee. The 260 u-joints from that particular axle have been replaced with Wrangler 297 u-joints and axles. Even though it will still be Dana 30 housing, the reverse cut and Dana 44 axles (along with doing away with the ZJ CV joints and going with forged u-joints) make it much more durable and better suited to turn my 35" tires. In addition, it now has a cable-operated Ox Locker. No o-rings or hoses to worry about, no switches or compressors - sometimes simple is better. There is no need for a diff guard either, because the diff cover that comes with this locker is made of 1/4" solid steel!

James at Marcy's Automotive & 4X4 in Evergreen, CO advised me on the selection of many of the parts and put it all together. I met him wheeling, and he has helped our group a number of times on the trail with broken down rigs. His expertise comes not only from being a good mechanic, but also from years of experience off-roading. He did an incredible job, and even stayed after hours to make sure that it was done right. James kept me posted on everything he was doing, and he patiently and thoroughly answered all of my questions before, during, and after the build. I will definitely be going back to him with any custom work that I can't do myself.

ZJ build, continued


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