Wagoneer Dana 44 front axle swap

[TexasTJ2004]

Absolutely. In my case, I don't have the ability/time to shorten an axle, so a TJ44 was the best option (aftermarket axles being another, but quite pricey). If you have the skills and spare time to build your own axle, go for it hands down.


This is my dilemma. Really want to try 5.89s, going in with the assumption that I'll need to get manual hubs, but slightly worried about the rear having vibes too. It's my understanding that the LJ's longer driveshaft doesn't help with those vibes either..

If you don't have high lift, and driveshaft angles are precisely correct, and the driveshaft is not too heavy and properly balanced, you should not have vibes at any speeds. The only factor that you don't really control is the driveshaft balance - I think that they are balanced up to 3000RPM, and with 42RLE and deep gears will get into 4000+RPM area easily.

 

[TexasTJ2004]

@mrblaine - question for my future plans - do you have Grand Wagoneer 80s brake upgrade recommendation?

 

[mrblaine]

@mrblaine - question for my future plans - do you have Grand Wagoneer 80s brake upgrade recommendation?

Maybe, I need the industry pad number.

 

[Rickyd]

Ford 44HP with narrowing - this is maybe the best option, but the most complicated one. Need to cut tubes, narrow them, then find shafts that will work for it (I assume it needs custom shafts, you cannot put into it the wagoneer shafts I assume), then weld.

It really isn't hard. Just time consuming. Grind the welds holding the inner c's on,knock them off,then cut off enough tube to make each side wagoneer width so you can use its shafts.(you can compare shaft widths and just remove the corresponding amount from each side).then knock the inners back on and clock them for desired caster. I second no truss.they take up room and aren't needed.

 

[pc1p]

Thanks for the info. When I look into front Dana 44 options (the only way to get the 5.38 gears for larger tires like 35s that I need with my 42RLE), the only options I see is TJ Rubicon Dana 44, HP Dana 44 from Ford and Wagoneer Dana 44.
TJ Rubicon Dana 44 front is a rare as unicorn and does not come with Manual hubs. Adding manual hubs to it is like 1K$ minimum. Brakes - running 35s will require Big Brake kit or something, which is around a 1.5K$. So, it is not really cheap, weaker tubes, similar to dana 30 tubes. I use manual hubs (YO WU07 kit from Yukon, the "Ranger hubs") on my Dana 30, and I want to keep having it in future.
Wagoneer Dana 44 - comes with hubs already (replacing worn out bearings in hubs is a piece of cake job), easily upgradable brakes etc. Need to match the rear axles as well, which can be Dana 44 wagoner or Isuzu Rodeo - provides the same lug pattern. Truss/Swap kit is 400$, labor for welding I will do myself, if not, welder charges 600$ to do swap per axle. There aftermarket Chromoly shafts for Wagoneer, as these are standard shafts.
Ford 44HP with narrowing - this is maybe the best option, but the most complicated one. Need to cut tubes, narrow them, then find shafts that will work for it (I assume it needs custom shafts, you cannot put into it the wagoneer shafts I assume), then weld. I believe that my welding skills are enough to weld a truss/swap kit onto shaved axle, but shortening axles seems beyond my personal capacity. Also, I don't know whether there is any swap/truss kit available to put this axle under TJ.

Cutting the tubes is relatively easy on the Dana 44. You essentially cut off the C from the end, trim up the tube as needed (a band saw works well but many options work), then reweld the C to where it needs to be. With some good measuring, or a willingness to experiement some, you could easily optimize pinion angle and caster all in one swoop.

@Wildman did a write-up a few years back: https://wranglertjforum.com/threads...nion-dana-44-front-axle-to-waggy-width.19445/

You don't need custom shafts - one of the main advantages to narrowing to "Waggy width" is to use OEM/off-the-shelf Waggy length inner shafts (use outer shafts that match your knuckle/spindle setup).

You don't need a truss and any swap kit meant for 3" tubes should work just fine.

 

[pc1p]

@mrblaine - question for my future plans - do you have Grand Wagoneer 80s brake upgrade recommendation?

OEM Pad for JB6 is D52S - alternative OEM option is to use a D614 pad, which is the "Police and HD package" brake pads that fit into the JB6 caliper. They have plenty of bite but also have a good feel (at least on my old 95 YJ, which is similar to most TJs).

 

[Rickyd]

OEM Pad for JB6 is D52S - alternative OEM option is to use a D614 pad, which is the "Police and HD package" brake pads that fit into the JB6 caliper. They have plenty of bite but also have a good feel (at least on my old 95 YJ, which is similar to most TJs).

Yj master and booster?

 

[JulianCordova]

Guys, I need your advice on Wagoneer axle swap. I was looking into Dana 44 options that can fit TJ, and found Wagoneer Dana 44 front axle. It fits width wise, and seems to be strong.
I am looking into running 33s or 35s in future, and want to have the option of switching to 5.38 gears in future, which is not possible with Dana 30.

I have TJ Dana 44 for the rear, which can be upgraded even to 35s, with 4130 chromoly (which is real chromoly, unlike other stuff that claims to be chromoly, when it is not).
Have anyone here did this swap? What are brake and steering options for it?

I've done it only to end up with a bad case of death wobble on freeway it really dose put a toll on the rear gears as well so I had to drop back down to 33s

 

[pc1p]

Yj master and booster?

Yes (sorry, I'm slow to check and update lately - busy bee )