The good old Dana 44a discussion again ;-)

[Buzze]

Hi folks I would love to hear some opinions for my 96' Zj 4.0 fix. I don't want to call it build because I try to fix a couple of issues and love to read all your experience to upgrade while I fix it myself. Also it is time to get her on the trails to find out why it is a 4X4  .
So far I fixed: coil spacers to front front springs to back to get my used mfg at 10.5 31" tires on. Tie rod ends came with a V8 steering. The loose steering gear box got replaced with a Durango box. Disconnect sway bar links came cheaper than the 3rd change of stock links. Got a new track bar to get rid of the death wobble. Steering damper is ordered to get the last little bit of vibration out of the front end. Wheel bearings and ball joints got replaced last year and teamed up with some Billstein shocks. U- joints and new front diff gears (3.73) was also a need a year ago.  And from here on it turns into over detailed blabla I guess.
Long story short.
 I'm a drive way mechanic not more and my welder buddy will help me with some custom armor.
She will become a functional rig to introduce myself to the scene. We will find out how deep we get into it and what rig will be the next.
Back to the topic.
The axle shaft on the rear end dana 35 got a stroke when a young lady hit me on the wheel with her Prius a while ago, so the bearing is shot by now as well. The other side bearing is also not really tight. I got a new axle shaft from pick and pull BUT another buddy has a dana 44a out of a 98' 5.9  with 3.73 ratio I could have (perfect match next door).
First I thought about changing the whole assembly to the 44a than I read about the weakness of the aluminum unit but a 35 is obviously also not the titan of axles. The 35 has no locker the 44a would have. Also I will get some bigger discs with the 44a. I'm aware of the longer pinion so far but have an Idea to work around it. I don't want to get a lot of welding modification involved to get a ford 8.8 in so what would you do? There is no bolt in 44 option as I understand. So basically it is about what to do with what you have.
I appreciate any comment one way or the other because I' m unsure. I will get the axle shaft in for now to have the wheel run straight again for a start. Changing the bearings will sit on the back burner for now to find out if someone will recommend to bolt in the new assembly and fix the bearings on the new set up, if required. I can think of a custum truss if really recommended.
Or maybe someone has something else to get more option to the decision making.
Thanks for all your time to read this and all your input.
I hope we will see us on the trails soon.

[JackstandJohnny]

find another D35 and run that. plentiful cheap and easy to fix when/if you grenade it.

31s will be fine on it.

google 'D44a swap + jeepforum'

you will find a lot of threads on this, and the general concensus will be:

D44a is not much better than the D35.  D44a has weak axletubes that cause the carrier to eat bearngs and screw up the housing.  there is no aftermarket support for it really. just a couple lunchbox lockers.  the D44a from the 5.9s came stock with a limited slip (this is not a locker) and if you want to put an actual locker in, you will need to swap to an open carrier and new axleshafts..........

lastly, its not a cheap upgrade, and marginal in strength. as you said you'll have to fab up a pretty stout truss to cancel out any of the axletub flex from the centresection, which cost time and money to weld up......... if you're gonna do some welding, why not just swap an 8.8" or a 9"? the IRO bracket kit took a couple hours to install on a bare axle...........

hope this helps........... again, D44a ain't worthit.

[Buzze]

Good point on your comment (sometimes I don't hear my self) , no welding work for a new axle, but ready to put a custom truss to the 44a??? doesn't make sense does it. Thanks for reading and considering my needs. I guess you nailed it, I don't need a pit bull axle for a little bit of trail riding on 31". If we go harder I will consider to follow your writeup about a 8.8. You saved me a lot of nonsense work. Further comments are welcome, but I think my mind got adjusted correctly with this one already ;-). Cheers

[JackstandJohnny]

i posted the same question some time back trust me i went through all the trials and tribulations of the swap.  keep it stock or go big   good luck with it!