30 spline Dana 30 Revolution shafts and manual hubs

[Thunder Mass]

I've ordered most of the parts I need for my build, including the ARB lockers front and rear (Dana 30/44) but I still need the Revolution shafts. I haven't ordered them yet because they're currently out of stock with the Dana 44 rear. But I got to thinking; instead of 27 spline for the 30, should I upgrade to 30 spline? The locker that I have ordered is a 27 spline, but it shouldn't be too late to swap it for a 30. Besides the locker and axle shafts, is there anything else I'd need to change? As I'm writing this, I'm thinking maybe the unit bearings? But I think the outer shafts are still 27 spline, so, I guess not. But if the outer shafts are 27, is there really any benefit? Since I'm replacing the shafts and carrier, I figured I'd look into this option. Only con is, I can't use my stock shafts as spares.

With the revolution, I was going to go with these in the front:
https://www.4lowparts.com/shop/dana-30-front-axle-kit-discovery-series/

But another option would be these:
https://www.4lowparts.com/shop/dana-30-front-axle-kit-tj-lj-xj/

Only difference I can see is that the latter are American made, and use the 1350 U-joint vice the 5-760. And, they're some $300 more. For those reasons, are these worth it? I'm assuming there's no issue with them fitting.

The last question is about running manual hubs. I'm NOT looking into it for the sake of improved MPG; I understand that it either won't happen, or is so small, you can't tell. That's fine. What I like about it is that if I do break something in my axles, like a shaft or ring, I can still potentially drive or tow it home safely without ruining the axles further. Some of the manual hub kits are a bit pricey, but also come with rotors, outer shafts, and U-joints, that I was already going to replace anyway. Like this:

https://www.quadratec.com/p/yukon-g...-jeep-wrangler-tj-yj-cherokee-xj-dana-44-dana

Rather than getting a full kit, can I just get what's missing? Or, are the rotors, shafts, and U-joints not compatible? This would be a question for MrBlaine, but do the manual hubs work with his brakes?

I don't need to do the manual hubs now; just wondering if I'll be throwing away anything if I do them later. And, I don't really see much on it, but can I do rear manual hubs as well? For the same reason as the front. And, maybe it makes flat towing easier?

Thanks guys.

 

[Jerry Bransford]

Manual hubs work with Blaine's BM brakes, I've run both the big hub and small hub kits with mine.

Unlocking a hub to get you home after a breakage isn't going to work for most breakages, especially if you don't have a selectable front locker. The broken parts would likely grind against each other unless you had a front selectable locker you could unlock plus unlocked manual hubs. But getting home by removing the inner shaft to prevent problems is an easy job that doesn't take long which negates the need for either.

27 spline vs. 30 spline... I had 27 spline 4340 shafts and Warn's small hub kit on my previous TJ and now run 30 spline 4340 shafts with Warn's big hub kit on my present TJ. Warn's small hub kit like I used to run is essentially the same as Yukon's 27 spline hub kit in that Quadratec link. It's fine for even very tough trails, a locker, and 35" tires. I don't know that I can say there's enough benefit to the 30 spline version to warrant it when running the TJ Dana 30 or TJ Rubicon Dana 44. Plus you can buy a spare small hub as a quick/easy swap should you break a small hub on the trail. Possible with the big hub kit too but it's not as easily swapped.

I personally haven't seen enough benefit to rear manual hubs to have ever wanted them.

 

[Thunder Mass]

Manual hubs work with Blaine's BM brakes, I've run both the big hub and small hub kits with mine.

Unlocking a hub to get you home after a breakage isn't going to work for most breakages, especially if you don't have a selectable front locker. The broken parts would likely grind against each other unless you had a front selectable locker you could unlock plus unlocked manual hubs. But getting home by removing the inner shaft to prevent problems is an easy job that doesn't take long which negates the need for either.

27 spline vs. 30 spline... I had 27 spline 4340 shafts and Warn's small hub kit on my previous TJ and now run 30 spline 4340 shafts with Warn's big hub kit on my present TJ. Warn's small hub kit like I used to run is essentially the same as Yukon's 27 spline hub kit in that Quadratec link. It's fine for even very tough trails, a locker, and 35" tires. I don't know that I can say there's enough benefit to the 30 spline version to warrant it when running the TJ Dana 30 or TJ Rubicon Dana 44. Plus you can buy a spare small hub as a quick/easy swap should you break a small hub on the trail. Possible with the big hub kit too but it's not as easily swapped.

I personally haven't seen enough benefit to rear manual hubs to have ever wanted them.

Do you know if I'd have to get the full kit like in the link, and use their U-joints, shafts, and rotors? Or, can I just get what is in the kit minus the previously mentioned pieces?

I will be putting a selectable locker in the front; ARB. I didn't think about just pulling the inner shaft. But if the break is on the diff itself, then unlocking the hubs would be a benefit?

Okay, if there's not much benefit, I think I'll keep the 27, so at least I can re-use my old shafts if need be, if I break something.

I just thought that, if unlocking hubs in the front would help get you home easier, than they'd have the same benefit in the rear.

Thanks