By Phil Howell
photographer: Phil Howell
Part 1:http://www.4wdandsportutility.com/tech/0808_4wd_jeep_wrangler_yj_dana_44_axle/index.htmlThe word is out. Mopar is selling JK Wrangler Rubicon Dana 44 complete axle assemblies, and they're a very good deal. For a total of approximately $3,000, both front and rear Rubicon Dana 44s that come complete with disc brakes, electric lockers, and 4.10 gears will be delivered to your home or dealer ready for installation. These Dana 44s are direct bolt-ins in JK Wranglers, so owners of X or Sahara trim levels can easily upgrade their front and rearends to the Rubicon level and will even be able to use their locking differentials at any speed, in two-wheel drive, four-wheel high, or four-wheel low range. This is something Rubicon owners can't do as they're limited to using their lockers in low range. Mopar/Jeep JK Rubicon Dana 44s are available from any Mopar/Jeep Performance dealer.
These axle assemblies will also work in any other vehicle you choose to install them in with some modification. We followed our friend Eric Maughan as he ordered Mopar JK Rubicon Dana 44 axle assemblies and proceeded to put them under his '91 YJ Wrangler. 4 Wheel Drive Hardware has everything needed for a successful axle swap, such as a Mopar wiring harness that has the correct electrical plugs needed for the electric lockers. While doing the swap, Eric decided to install an Atlas transfer case from Advance Adapters too. Tom Wood's Custom Drive Shafts built new front and rear CV driveshafts that work with the Rubicon axle assemblies. Follow along, and we'll show you how easy this swap is to perform.
Part 2:http://www.4wdandsportutility.com/tech/0812_4wd_1991_jeep_wrangler_yj/index.htmlIn case you missed it in the Aug. '08 issue, we did a feature on installing Mopar's JK Rubicon Dana 44s in a YJ Wrangler. Complete JK Wrangler Rubicon Dana 44 axle assemblies are a great deal for those looking to upgrade their front and rearends. They come complete with disc brakes, electric lockers, and 4.10 gears and are a bolt-in deal for JK Wrangler owners.
Our friend Eric Maughan of Wellsville, Utah, ordered his Mopar JK Rubicon Dana 44 axle assemblies from 4 Wheel Drive Hardware and installed them under his '91 YJ Wrangler. In the Aug. '08 feature, we showed how Eric removed the JK bracketry from the axles, welded on spring pads, installed the ARB Air Locker switches for locker operation, and adapted the Mopar harness he got from 4 Wheel Drive Hardware that has the correct electrical plugs needed for the electric lockers.
Eric also installed a 4.3 Atlas transfer case from Advance Adapters. Mount Logan Off-Road supplied its super-strong aluminum tie rod and drag link. The guys at Tom Wood's Custom Drive Shafts rebuilt and modified the front and rear CV driveshafts to work with the Rubicon axle assemblies and also sent a pair of their JK Dana 44 pinion flanges.
Eric's YJ uses Rubicon Express spring-over leaf packs and also has a Vanco hydroboost system for the brakes. We mention this as his swap won't be exactly like yours, but it did show how relatively simple it is to do.