Steve's 1998 Wrangler axle swap and build

[SteveBarrus]

The Build starts tomorrow 1/28/19.

1998 Wrangler Sport 235000 ish miles, Dana 30/35 3.07 open axles

So far 3.5 OME Lift, 15x33R12.5, heavy duty front & rear bumpers, winch.

To come;
Dana 44, 4.10 Rubicon air locker, disk brakes, rear axle swap
HP Dana 30, 4.10 E-locker,
Alloy USA chromoly front manual locking hub conversion
Vanco 16" Big Brake kit
Dana 300 with Behemoth flip kit, JB conversions 32 spline front and rear outputs, 4-to-1 Low Max gears, AA flip ring and dual cable shifters.
Engine - timing chain, water pump, radiator, all fluids, o2 sensors, belts, idlers, exhaust

 

[Squatch]

I have a '98 Sahara, as well. Same color. I see you must be from the wet side of Washington. Where about, if you don't mind me asking?

 

[SteveBarrus]

North Bend, snuggled in the mountains.

 

[Squatch]

North Bend, snuggled in the mountains.

Nice!!!

 

[Chris]

Looking forward to the build!

 

[SteveBarrus]

I have a '98 Sahara, as well. Same color. I see you must be from the wet side of Washington. Where about, if you don't mind me asking?

Very nice to meet you. Have you done the Washington Back Country Discovery Route? Plan on doing it this summer

 

[Squatch]

Very nice to meet you. Have you done the Washington Back Country Discovery Route? Plan on doing it this summer

My '98 is in the garage with the rear axle out of it, and a ton of parts waiting to go on. I've been acquiring quite the supply of parts over the course of a year. Just need the time to get 'em on there. As for the WBCDR, I've seen a few videos on that. It definitely is something I want to do, though it's unlikely it'll happen this year.

 

[SteveBarrus]

The Rubicon Dana 44 was cleaned up and primered. No oil just dirt. I washed it with simple green and a stiff bristled brush to get it clean. Hosed down and brushed again. Let it air dry and primered. Tomorrow two coats of black paint then gear her under the TJ.

 

[astjp2]

Skip flipping the 300, I tried it on a YJ, bought an atlas to get the shifters to actually work.

 

[SteveBarrus]

Got the axle painted, carpet removed and new low back black seats installed. The old seats suffered 200,000 plus miles with 350 lbs riding in them. Eventually I will get the floor sprayed with black liner. But that will come after.

I will pick up the new to me, 90,000 mile hp Dana 30 tomorrow and prep to swap rear axles Thursday.

 

[Squatch]

Nice low backs, Steve. What are they out of? Or are they aftermarket? I actually prefer low back buckets to high backs, but I do understand the safety benefits of the high backs. Anyway, they look great!

 

[SteveBarrus]

Nice low backs, Steve. What are they out of? Or are they aftermarket? I actually prefer low back buckets to high backs, but I do understand the safety benefits of the high backs. Anyway, they look great!

After market from 4wheel parts. I like to easily see behind me when out in the woods. Lol

 

[SteveBarrus]

Finished prepping the Dana 44 for tomorrow’s installation. I got adjustable upper and lower with Johnny joints.

Also picked up my gift front HP Dana 30 and tore her down so I can get her rebuilt next.

 

[SteveBarrus]

It has been slow as of late. 40 inches of snow when we generally do not see snow. Three weeks later still 8 inches of snow. I do not have a garage so Jeep is sitting on blocks in 8 inches of snow with out a rear end. But on the positive Got my beautiful Behemoth Drive train flip kit, AA flip ring, twin cable shifters, JB Conversions LOMAX 4 to 1 gears, 32 spline front and rear kits. so this week I will build the Dana 300. Also got the RCV axles, OX Locker & ring and pinion. wooo hooo I am off all week.

 

[73Carlow]

re

Got the axle painted, carpet removed and new low back black seats installed. The old seats suffered 200,000 plus miles with 350 lbs riding in them. Eventually I will get the floor sprayed with black liner. But that will come after.

I will pick up the new to me, 90,000 mile hp Dana 30 tomorrow and prep to swap rear axles Thursday.

View attachment 74975

View attachment 74976

really like these low back seats

 

[SteveBarrus]

re

really like these low back seats

The low back seats let me have full view of everything around the jeep that the high back blocks.

 

[SteveBarrus]

Finished prepping the Dana 44 for tomorrow’s installation. I got adjustable upper and lower with Johnny joints.

Also picked up my gift front HP Dana 30 and tore her down so I can get her rebuilt next.

View attachment 75083

View attachment 75084

Continued working on the Dana 30 HP. Removed everything, pulled the axles and marked the caps. R&red everything inside keeping the pinion and bearing shims separated. Cleaned and painted the front end. Adjusted the clearances and I nstalled the new 4.1 ring & pinion on the new OX locker. The inner seals were a challenge, I finally turned my seal set with the handle through the seal, put a 1” pipe down the axle and pounded the seal in place.

 

[SteveBarrus]

The Dana 300 is coming along. Got it torn apart, cleaned, washed, primed and painted. The lomax gears are scheduled for delivery tomorrow and assembly will begin. The Behamoth flip lid is perfect for bringing the shift assembly to the new top. The shifter holes will be tapped 1/2 NPT and plugged with silicone on the threads.

 

[SteveBarrus]

Dana 44 Rubicon axle going on.

 

[TJ Hunnicutt]

I can see we are cut from similar cloth, anal retentive as hell!

I admire your ability to work in the snowy temps . Looking mighty fine!!

EDIT: Nice work on the diff gears...right smack in the middle