Tons... what more needs to be said

The holy grail of the offroading world

I am going to try to provide the simplest and most to the point parts list of how to 1 ton swap your XJ with the only extra requirement being your ability to spend money and do your own fab work.

The Simple Way

Front Axle

  • Your choice of ball joint dana 60 from a Ford
    • 2005-present
  • Barnes XJ/MJ/TJ/WJ swap truss
  • OEM Ford Steering 
  • extended brake lines
    • they screw right on the jeep hard lines
  • your choice of long arms
    • preference of Jhonny joints or enduro joints
  • a custom driveshaft
    • cannot use stock front, the pinion is too long on the D60

 

Rear Axle

  • 2005-2010 Sterling 10.5 
  • Barnes anti wrap spring perches
  • a 3/16 female-5/16 male brake line adapter
  • new pinion yoke that accepts a 1350 U-joint
  • a 1310 to 1530 conversion joint
    • this allows the front driveshaft to be reused
  • a SYE kit installed on the transfer case 

Other Parts

Same year as your jeep RAM 2500 VAN master cylinder needed

 

The Complex Way

Steering

  • Heim joint Tie rod kit
  • Preferred brand of weld on high steer
    • use a crossover version to get the best steering angle possible
  • Preferred brand track bar bracket (frame side)
  • 1 weld in RH or LH Heim joint kit
  • 1 weld in 7/8ths tapped bung (opposite of previous
  • same hand thread tie rod end
  • some 1inch ID tube

Front Axle

  • Favorite Ford Dana 60
    • 2005-present
  • Low profile D60 truss (with over axle track bar bracket)
  • lower control arm brackets
  • upper control arm brackets
    • Preferably johnny joints
  • Extended brake lines

Rear Axle

  • Favorite Sterling 10.5 2010 and older
  • Narrow sterling truss
  • Upper link brackets
  • lower link brackets
  • materials for links
    • tubing or machined aluminum
    • 4 joints 
    • 4 bushings
    • (Use minimum of 1 1/4 threaded ends

Ironman 4x4 Fab makes a full belly kit that does front and rear links

  • shock brackets
  • Rear Coil brackets/ universal coilover brackets
  • 3/16 female to 5/16 male brake line adapter in whatever flare your axle and jeep has

 

Extra Necessities

  • Stiffener plates
  • shackle relocation brackets
  • steering box brace
  • GM 1 ton tapered reamer 7°
  • Preference of front long arms
  • same year Ram 2500 Van brake master cylinder

Questions?

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