TJ Axle Swap (D30 to D44)

[Impact]

Hi,

I am looking to upgrade my suspension in my 05 TJ to a run 36's or so. I currently have the stock
D30/D44 axle setup. My question is, what isthe strength difference between my stock D30
compared to a D44 from lets say an 05 Rubicon?
Is it possible to just order the axle housing from the dealer and just build the axle from there
or would I have to buy the entire axle assembly?
Whats the strength difference between my stock D30/44, Rubicon 44/44 and Ford 44/9 combos?

[dac]

Cost wise it'd probably be cheaper to order a complete assembly aftermarket with what you want than order the housing from a dealer, if the dealers can still get them.  I was told, when I started looking for a rear D44, that they couldn't get them anymore; just for the jk's now.

[FullMetalJeep]

Ford 44/9 combos?

I think that combo is probably one of the deadliest combo's you could do from a scrap yard axle build!

1979 Ford Dana 44 HP front with a Ford 9 in the rear! oh baby! Just keep the track width... it's an extra 2 inches on each side.

[Bnine]

Simplest most affordable solution is a complete 44 front for a jeep from Northridge 4x4.

They are opening an outlet here in alberta shortly.

Something like a ford hp 44 is stronger, but a bit more work, and will require bolt pattern and rim size changes.

[Impact]

I think that combo is probably one of the deadliest combo's you could do from a scrap yard axle build!

1979 Ford Dana 44 HP front with a Ford 9 in the rear! oh baby! Just keep the track width... it's an extra 2 inches on each side.

Whats the strength difference between the combos though? I have heard that the Ford 44 isnt much stronger
that a d30... not worth the swap. Is my source wrong?

[raf2379]

Whats the strength difference between the combos though? I have heard that the Ford 44 isnt much stronger
that a d30... not worth the swap. Is my source wrong?

I've been doing a lot of reading on the combo swap, and from all the sources I've gathered that the ford HP D44 is a bit stronger than the D30. a good strong axle to get is out of a 1973-1975 Ford F-100 which have the weld on wedges that can be cut off, the late 70's front ford D44 had the cast wedges and would require re tubing. the axle tubes are 2.75" with 0.5” thick walls and the 5-260 Cardan joint from 1971 to 1972 and changed to larger larger 5-297 Cardan joint from 1973 to 1975. the shafts are 1.31" 30 spline 8.5" ring gear. these axles are rated at continuous output torque of 1,100 ft/lbs and maximum output torque of 3,460 ft/lbs

as for the Dana 30, it has same Cardan joint 5-297, but the axle shafts are only 1.16" 27 spline with a 7.13" ring gear, the axle tubes are 2.5" with 0.25" thick walls. these axles are rated at continuous output torque of 640 ft/lbs and maximum output torque of 2,350 ft/lbs. The 5-297 Cardan joint yield strength is rated at 1,600 ft/lbs and ultimate tensile strength of 4,600 ft/lbs. the Cardan joints can be upgraded to a CTM, OX or Yukon which are said to be 2 - 3 times stronger.

to me the front HP D44 is quite a bit stronger, which changed my decision on building up my front D30 for my XJ. In my opinion it will cost only a little more to build up a Ford HP D44 than the D30.
 It wouldn't really be necessary to truss the front D44 as it would the D30 due to the thick walls of the axle tubes.


the Rubicon D44 has the same size axles as the Ford D44 at 1.31" 30 spline 8.5" ring gear i'm just not sure on the axle tube diamiter and wall thickness

also here are some numbers for the axle size strengths.
 this is an aproximate yield strength in ft/lbs

D30 minor spline diamiter  is 1.11-inch 1040 carbon steel 2,371

1.18-inch 1040 carbon steel 2,835 5
1.18-inch 1050 carbon steel 3,939 
1.18-inch 1541 carbon steel 4,424 
1.18-inch 4340 alloy 5,665
 

1.34-inch 1040 carbon steel 4,174 8
1.34-inch 1050 carbon steel 5,738 
1.34-inch 1541 carbon steel 6,446 
1.34-inch 4340 alloy 8,254

[adamnigh]

do the complete 44's from northridge come with all the shock brackets and coil plates on them, or do you have to put them on. anyone know?
-Adam

[BlackYJ]

The HP D30 would be another good choice and can be made as strong as the rubi D44 because of the reverse rotation gears.  I have seen several people run 35-37" tires with a D30 stock and upgraded.  You can upgrade the D30 shafts to D44 shafts as well.

[Impact]

Thanks for the replies guys!

Like someone posted, does the aftermarket axle from northridge come with brackets and etc installed?
Any cost ideas?
Too bad we couldnt all win the lottery.... lol!

[TJ54]

Al (fiend) did a hp 30 swap, when he gets back from his trip he may have some input on that.

[adamnigh]

I  have been speaking with stan via email all week about the complete Dana 44's from northridge, and yes they do come with all the bracketry to be swapped directly into a TJ. What do you guys all think about those prices, seems decent with chromoly axles and lockers front and rear.
-Adam Nigh

[Impact]

Northridge 4x4 isnt really an option for me as I dont live in the area any more...


Does anybody know if its possible to mount the brackets on a 44/9 axles in the same measurement
location as on stock TJ axles?