How Long to do a Dana 35 to Dana 44 Axle Swap?

[Jeffreybomb]

I found it on CL in Austin.

I've been combing CL for one, too. So far, no luck. I wouldn't even mind doing a road trip if I could find one at least in the region. Davey's Jeeps always wants $3,000+ for paired Dana 44 axles.

This has been a long quest. Hopefully I can finish up the swap tomorrow

I'm sure this goes without saying, but be sure to post pics.

It would be for me. The front axle seldom sees more than about 50% of the load/stress the rear axle does so it's normally good to go for up to 35" tires. Once you get both 35's and a locker into the front axle though it's time to upgrade its inner/outer shafts to 4340 alloys.

I'd like to get 35s eventually. I want to make sure I understand: I'd be okay with a stock Dana 30 and 35" tires without a locker? Would a front locker not do much more for the Jeep, assuming I've got a rear locker?

 

[Jerry Bransford]

I'd like to get 35s eventually. I want to make sure I understand: I'd be okay with a stock Dana 30 and 35" tires without a locker? Would a front locker not do much more for the Jeep, assuming I've got a rear locker?

Within reason, your front Dana 30 is fine for 35" tires so long as you don't also install a locker or give it too much gas in 4Lo when the wheels are cranked hard over. The front axle's u-joints and axle shaft ears that hold those u-joints are at their highest stress when the steering wheel is turned hard left or right.

It took me a while to finally break one of my previous TJ's front Dana 30 axle shafts with 35's and a locker.

 

[Jon Wildes]

I've been combing CL for one, too. So far, no luck. I wouldn't even mind doing a road trip if I could find one at least in the region. Davey's Jeeps always wants $3,000+ for paired Dana 44 axles.



I'm sure this goes without saying, but be sure to post pics.



I'd like to get 35s eventually. I want to make sure I understand: I'd be okay with a stock Dana 30 and 35" tires without a locker? Would a front locker not do much more for the Jeep, assuming I've got a rear locker?

I called Mr. Complete I Memphis today and they have a couple Dana 44 on hand. He told me $1500 over the phone. http://www.creepersjeepers.com/

 

[Andy Maurer]

The OE driveshaft should be good to go for your Dana 44 so long as you have some suspension lift installed.

I did this same job recently and used the OE driveshaft, my jeep has zero suspension lift. It was a tight fit, but I was able to get everything connected and has been working fine since.

 

[Jerry Bransford]

I did this same job recently and used the OE driveshaft, my jeep has zero suspension lift. It was a tight fit, but I was able to get everything connected and has been working fine since.

You might find yourself with a seriously expensive axle or transfer case repair if you take a dip or bump in the road hard enough to need to compress your incompressible rear driveshaft.

 

[Jeffreybomb]

Within reason, your front Dana 30 is fine for 35" tires so long as you don't also install a locker or give it too much gas in 4Lo when the wheels are cranked hard over. The front axle's u-joints and axle shaft ears that hold those u-joints are at their highest stress when the steering wheel is turned hard left or right.

Good to know.

It's a lot easier to justify this entire project if I'm able to do it in stages instead of trying to do everything at once.

The only "repeat" I can think of would be removing the front axle to regear (matching whatever I put in the back), putting it back in, and then removing it to replace the front axle with something stronger later. I'm moving at a snail's pace already, though, so I'm not overly concerned about that.

Damn you, real life and adulting!

 

[Andy Maurer]

You might find yourself with a seriously expensive axle or transfer case repair if you take a dip or bump in the road hard enough to need to compress your incompressible rear driveshaft.

This one comment was all the push I needed to finally order the lift I have been looking at for a couple months now Adding 3 inches of suspension lift should take away any issue of a an incompressible rear driveshaft!