Author Topic: TJ Dana 44 Front Axle  (Read 4291 times)

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Offline jagular7

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Re: TJ Dana 44 Front Axle
« Reply #30 on: March 05, 2008, 09:04:06 AM »
Hah hah.  You've been talking about these axles for at least a year are you ever going to install them?   :beers:  If I wanted to put 60's in I would save up and do it.  Don't need them though it would be a waste of money, I actually plan on staying with my 4 cylinder and not going larger than 35's.  If I ever want something bigger I'll build a buggy.

If you are not going any bigger than 35's and keeping the 4cyl, I strongly suggest you rethink the expense you are going through. From what I've read, you want a differential housing that would give you 5.38s and work with the stock D30 knuckle out. Problem there would be the inner axle length as it could become a custom length, thus requiring machine work. If you break a u-joint, most of the time, you break/mess up the ears on the axles and need to replace both of them. However, it's highly unlikely also, (very driver dependent), that you would break an u-joint and thus both axles. But, it still could happen.

Now, Dodge has been selling the newer JK front and rear axles with gears and lockers in the ready to bolt in and go. They are 5 on 5 lug pattern. They are 5" wider (someone stated under 3" but no clarification on which is correct*). Supposedly, the locations for the coils, control arms, and track bar do not need relocation. They are D44 housings, front is high pinion. Since they are still fairly new in the market, aftermarket will probably have different ratios/lockers available soon enough.

I'd see about if these JK axles would work with the TJ D30 knuckles out. That would be a fairly good swap to the TJ. Using stock TJ components where needed to keep costs down, empty axle housings from Jeep with inner axles (or look for aftermarket alloys) will keep costs down, you getting your own gear/locker and install will keep costs down, and you can actually keep you Jeep on the road during the install since the suspension components won't need relocation. So it may only take a day to swap out the axles, remove/install knuckles, etc. Not bad for a weekend.

Now, another viable option and probably a way to make some money at it is to come up with a gear case that is 30% lower than 1 (1.3:1). This is what 5.38 ratio is to the 3.73 ratio (assuming what was stock in the 4cyl TJ). This would be pretty simple and you wouldn't have to make it have any real length, maybe 2-3+ inches. The gear case would be similar to that of the Klune, but you wouldn't be as long as you only have 1 gear ratio change using the planetary gear setup. Place this between the trans and t-case.

My followup question is to why do you need the 5.38s in the axles (did I miss it)? Is it for 2wdhigh or the 4wdlow side use? If 4wdlow, you can getter low gear ratio for the TJ's 231 case. 4:1 is rather easily available, its a bolt in situation, and a much better option for your money's worth?
You could also look at D.D. Machine's doubler for the 231 as a way of getting better low side gear ratios.


*Not to push to another forum, but JeepsUnlimited has someone that install JK axles into a TJ w/ pics.
Jagular7
97 SE - Rubbered and locked for fun
94 SE - stock, collecting parts for 37s

Offline oldjeep

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Re: TJ Dana 44 Front Axle
« Reply #31 on: March 05, 2008, 09:24:51 AM »
Or just put the 35's on, realize that you don't need 5.38's and save all sorts of money.   :pot:
Chuck P
The clowns'? Oh, yeah, the clowns. We fight them too — entire armies, spilling out of Volkswagons. We do our best to fight them off, but they keep sending 'em in!
94 YJ - gone
98 ZJ - sons truck
97 TJ - daughters project

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Offline Mozman68

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Re: TJ Dana 44 Front Axle
« Reply #32 on: March 05, 2008, 11:23:31 AM »
I know...I'm all talk and no do....but they are actually going in....Just one more month to wait....and I'll be running my 4-banger with 35's....for now
2009 Audi S5....what....its 4wd...sort of....

jcsanders79

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Re: TJ Dana 44 Front Axle
« Reply #33 on: March 05, 2008, 04:14:16 PM »
I'm done with this Q. I am on another forum and am getting answers not critism :twofingers:.  I happen to have a 4:1 on order and it should be here within 4-5 weeks.  If anyone is considering one I would give www.samsoffroad.com a look (I've done business with them in the past and they are top notch).  They have a blem special that is $729 TYD.  The 5.38's are for 2wd.  If you think I don't need them thats fine I, I am pretty sure that I have seen quite a few guys that run 35's with 4.88's (which I have now) say they wish they had 5.38 gears.

jcsanders79

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Re: TJ Dana 44 Front Axle
« Reply #34 on: March 05, 2008, 04:23:07 PM »
Forgot to mention I don't know how far I will get with this in the next few months.  I found out today that I will be having my gallblader removed in the morning and my copays for surgery will most likely zap my fun money :brick:.  Maybe not we'll see, thats the benefit of building it myself instead of buying it all fabbed up.  I can do it couple hundred at a time.

Offline Bounty Hunter

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Re: TJ Dana 44 Front Axle
« Reply #35 on: March 05, 2008, 05:20:36 PM »
I run 5.38 and either 35" (onroad) or 36" (offroad) tires, and would not run a taller gear.  5.38 puts the 2.5L in an awesome powerband for highway and offroad use.

Why not just install junkyard D44's on each end and forget trying to modify a front D44 for the puny 5x4.5" lug pattern.  Going with a standard D44 knuckle will get you the benefit of cheaper highsteer options, serviceable bearings, and locking hubs.

I went with a Waggy front D44 and Isuzu rear D44, both with matching 6-lug wheel pattern and disc brakes.  The 'Zu D44 is a great match for the Waggy axle.

Don't listen to the criticism, just weed through it for the useful info.

Good luck with the surgery.

Offline Mozman68

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Re: TJ Dana 44 Front Axle
« Reply #36 on: March 05, 2008, 06:31:01 PM »
hmmmm....I'm starting to worry about my 35's and 4.88's....actually, I'm more worried about them and the added weight of my axles.   ::)
2009 Audi S5....what....its 4wd...sort of....

Offline Bounty Hunter

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Re: TJ Dana 44 Front Axle
« Reply #37 on: March 05, 2008, 06:35:08 PM »
I wouldn't go with a 4:1 in the transfer case unless crawling is all you do.  Around here 2.72 works real well for general trail riding, which includes high revving hill climbs and mud runs, not just slow technical rock work.

jcsanders79

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Re: TJ Dana 44 Front Axle
« Reply #38 on: March 05, 2008, 06:48:18 PM »
I wouldn't go with a 4:1 in the transfer case unless crawling is all you do.  Around here 2.72 works real well for general trail riding, which includes high revving hill climbs and mud runs, not just slow technical rock work.
Got a lot of rocks around here, have you heard of Telico?  For the most part I stay out of the mud.  I do most of the high rev stuff in 4WH anyways.

Offline jagular7

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Re: TJ Dana 44 Front Axle
« Reply #39 on: March 05, 2008, 07:40:08 PM »
Here is the discussion on the JK D44 axles in a TJ. They also have an extensive discussion on gear ratio matching tire size.
Jagular7
97 SE - Rubbered and locked for fun
94 SE - stock, collecting parts for 37s

Offline Bounty Hunter

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Re: TJ Dana 44 Front Axle
« Reply #40 on: March 06, 2008, 12:20:52 AM »
Here is the discussion on the JK D44 axles in a TJ. They also have an extensive discussion on gear ratio matching tire size.
Tire size is not the only factor to consider when determing a new ratio.