I need to rebuild my front axle bad - one of the carrier bearings is eating through it's race. I've been doing some research on what I want to do when I rebuild it as it's expensive, and while I think I have a plan in place I wanted to make sure what I'm doing is sound and makes sense.
The jeep - 97, 4.0, AX15, Dana 30/35, 3.55 gears. Currently running 31s. Decent possibility I move up to 33s after a lift, tummy tuck, etc. Less likely I end up on 35s - if I do it won't be for at least 3-4 years based on my current trajectory. I wheel in the Rockies so a decent mixture of Forest Roads, rocky trails, and there is rock crawling out here I'd like to start getting into/building for (thanks, Moab). I "daily" my jeep as well, but I WFH so by "daily" I mean I drive it within a mile to the grocery store once a week...
I'll start off talking about what my current plan is. I am thinking of keeping the axles, the 30/35. The idea is to get the "master rebuild kit" and have them both rebuilt, both re-geared (thinking 4.88 or 5.13, see question section below lol), an Eaton E-Locker in the rear, and a new lunchbox locker in the front (Currently have one, will need to get a new one since carrier cutoff is between 3.55/3.73). This will run me around $3500ish, every reputable store in my area I've found is pretty similarly priced.
The questions I am hoping you guys can help me out with to make sure I'm doing the "right" thing here (this is a lot of money for me ha) are:
What Axles should I use?
Am I going to regret building a Dana 30/35? I've read on the forum that the super 35 is adequate up to 35s, which I'm not sure I'll even get to. So I'm thinking I'm okay with these - but maybe not. The other options are dana 44(s) from a TJ (Which will turn this from ~3k to ~6k, I cannot afford this option), or:
Ford 8.8 (rear) : Sounds like it used to be an option to add strength, but it hangs lower than the 35 and with a super 35 the 8.8 isn't significantly stronger? It also can come with a LSD and disc breaks - neither of which matter to me - adding an E locker, and brakes are just a maintenance difference.
Dana 44/35/30 from a JK (front/rear) : is the 35/30 stronger on the JK? Is it worth changing a JK axle for a TJ? I cannot weld so I assume this will be fairly expensive. Does seem like 44s from JKs are quite a bit cheaper.
Dana 30 HP (front) : Dana 30 HP from an XJ. I hear it's stronger - how much stronger? Is it significant enough I should wait to find one, or is it a "nice to have" if I can find one reasonably priced?
Other axles (front/rear): I see Dana 60s from Fords, Dana 44s from like 80s Fords, things like this for sale for fairly reasonable prices (2-300$). Are these worth considering either, or is the weight + bracket welding not worth it? To me, they seem overheavy and oversized for my goals. But if the 30/35 aren't strong enough, maybe I have the wrong perspective?
Can I even use my Dana 30?
Maybe this should've been the first question. My Dana 30 is slightly bent according to Grease Monkey - my caster (I think that's the right measurement?) is 6.3º (left) and 6.4º (right). I have read axles can be straightened:
Does straightening an axle weaken it?
Can I straighten an axle bent to that extent?
Or, should I just buy a replacement since they're cheap. If that's the best solution, how can I ensure I don't buy another bent one?
What ratio should I go for?
I'm debating between 4.88 and 5.13. I'm leaning towards the 5.13. With the 2.72 TCase, altitude, and hills out here, I am thinking I am better off erring on the side of a "steeper" gearset. Any considerations I may be missing?
Anyways any help you guys have is appreciated - in these questions or things I might not even be thinking about (and should). This is almost as much as I bought the Jeep for so I want to be sure I do it right the first time lol
The jeep - 97, 4.0, AX15, Dana 30/35, 3.55 gears. Currently running 31s. Decent possibility I move up to 33s after a lift, tummy tuck, etc. Less likely I end up on 35s - if I do it won't be for at least 3-4 years based on my current trajectory. I wheel in the Rockies so a decent mixture of Forest Roads, rocky trails, and there is rock crawling out here I'd like to start getting into/building for (thanks, Moab). I "daily" my jeep as well, but I WFH so by "daily" I mean I drive it within a mile to the grocery store once a week...
I'll start off talking about what my current plan is. I am thinking of keeping the axles, the 30/35. The idea is to get the "master rebuild kit" and have them both rebuilt, both re-geared (thinking 4.88 or 5.13, see question section below lol), an Eaton E-Locker in the rear, and a new lunchbox locker in the front (Currently have one, will need to get a new one since carrier cutoff is between 3.55/3.73). This will run me around $3500ish, every reputable store in my area I've found is pretty similarly priced.
The questions I am hoping you guys can help me out with to make sure I'm doing the "right" thing here (this is a lot of money for me ha) are:
What Axles should I use?
Am I going to regret building a Dana 30/35? I've read on the forum that the super 35 is adequate up to 35s, which I'm not sure I'll even get to. So I'm thinking I'm okay with these - but maybe not. The other options are dana 44(s) from a TJ (Which will turn this from ~3k to ~6k, I cannot afford this option), or:
Ford 8.8 (rear) : Sounds like it used to be an option to add strength, but it hangs lower than the 35 and with a super 35 the 8.8 isn't significantly stronger? It also can come with a LSD and disc breaks - neither of which matter to me - adding an E locker, and brakes are just a maintenance difference.
Dana 44/35/30 from a JK (front/rear) : is the 35/30 stronger on the JK? Is it worth changing a JK axle for a TJ? I cannot weld so I assume this will be fairly expensive. Does seem like 44s from JKs are quite a bit cheaper.
Dana 30 HP (front) : Dana 30 HP from an XJ. I hear it's stronger - how much stronger? Is it significant enough I should wait to find one, or is it a "nice to have" if I can find one reasonably priced?
Other axles (front/rear): I see Dana 60s from Fords, Dana 44s from like 80s Fords, things like this for sale for fairly reasonable prices (2-300$). Are these worth considering either, or is the weight + bracket welding not worth it? To me, they seem overheavy and oversized for my goals. But if the 30/35 aren't strong enough, maybe I have the wrong perspective?
Can I even use my Dana 30?
Maybe this should've been the first question. My Dana 30 is slightly bent according to Grease Monkey - my caster (I think that's the right measurement?) is 6.3º (left) and 6.4º (right). I have read axles can be straightened:
Does straightening an axle weaken it?
Can I straighten an axle bent to that extent?
Or, should I just buy a replacement since they're cheap. If that's the best solution, how can I ensure I don't buy another bent one?
What ratio should I go for?
I'm debating between 4.88 and 5.13. I'm leaning towards the 5.13. With the 2.72 TCase, altitude, and hills out here, I am thinking I am better off erring on the side of a "steeper" gearset. Any considerations I may be missing?
Anyways any help you guys have is appreciated - in these questions or things I might not even be thinking about (and should). This is almost as much as I bought the Jeep for so I want to be sure I do it right the first time lol