Wagoneer Dana 44 front axle swap

[TexasTJ2004]

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?

 

[TexasTJ2004]

Wagoneer axle is low pinion, comes with manual hubs, so it eliminates any concerns with regards to high speed vibrations.

 

[Wildman]

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 did a Ford HP44 swap on my Tj but narrowed it down to Waggy width. I used Rubicon Express brackets for the front axle as it was the only option at the time.
How I setup mine is in the thread.

https://wranglertjforum.com/threads...-front-axle-to-waggy-width.19445/#post-546016

And then there is more in my build thread.
I have Chevy knuckles machined for flat top arms and then Chevy small bearing spindles with Ford hubs & rotors. I also have JB7 calipers on the front axle which are from a 1 ton Chevy. They have a larger piston than the JB6 caliper that came on the 1/2 ton.

Depending on which knuckles you run will determine what your steering options are.

 

[pc1p]

I can't speak specifically to a TJ swap, but I did Waggy swap my YJ. Overall it was a good option for me as it retained the Jeep width while giving me cheap and easily available hubs, significantly better brakes, factory 30-spline parts, and overall a beefier axle. I went with GM flattop knuckles, and DIY crossover steering. I even added a track bar to it eventually. I kept mine 6-lug and matched it up with a Rodeo Dana 44 rear. Overall, it was a pretty solid and reliable setup for 35"s. I used D617 brake pads instead of the standard D52 pads that come on the JB6 calipers and had no issues locking up 35"s at speed.



Overall I was happy, though if I were to do that again I probably would hold out for a D44HP from an F-150 and narrow it to Waggy width.

 

[P man]

What is the dana 30 doing wrong that you need to upgrade?

I am not against the wagoneer swap but I would recommend you pencil out the cost before you pull the trigger. In my neck of the woods a worn out Wagoneer dana 44 is $500 up. Then add in brackets, labor etx.

 

[JMT]

What is the dana 30 doing wrong that you need to upgrade?

I am not against the wagoneer swap but I would recommend you pencil out the cost before you pull the trigger. In my neck of the woods a worn out Wagoneer dana 44 is $500 up. Then add in brackets, labor etx.

He wants the option of 5.38 gears.

 

[P man]

He wants the option of 5.38 gears.

My bad I missed that

 

[TexasTJ2004]

I did a Ford HP44 swap on my Tj but narrowed it down to Waggy width. I used Rubicon Express brackets for the front axle as it was the only option at the time.
How I setup mine is in the thread.

https://wranglertjforum.com/threads...-front-axle-to-waggy-width.19445/#post-546016

And then there is more in my build thread.
I have Chevy knuckles machined for flat top arms and then Chevy small bearing spindles with Ford hubs & rotors. I also have JB7 calipers on the front axle which are from a 1 ton Chevy. They have a larger piston than the JB6 caliper that came on the 1/2 ton.

Depending on which knuckles you run will determine what your steering options are.

Small bearing spindles with Ford Rotors was in order to switch to JK style 5x5 bolt pattern?
Did you stick to OEM brake caliper and pads?

 

[TexasTJ2004]

Missed the JB7 calipers

 

[TexasTJ2004]

I can't speak specifically to a TJ swap, but I did Waggy swap my YJ. Overall it was a good option for me as it retained the Jeep width while giving me cheap and easily available hubs, significantly better brakes, factory 30-spline parts, and overall a beefier axle. I went with GM flattop knuckles, and DIY crossover steering. I even added a track bar to it eventually. I kept mine 6-lug and matched it up with a Rodeo Dana 44 rear. Overall, it was a pretty solid and reliable setup for 35"s. I used D617 brake pads instead of the standard D52 pads that come on the JB6 calipers and had no issues locking up 35"s at speed.



Overall I was happy, though if I were to do that again I probably would hold out for a D44HP from an F-150 and narrow it to Waggy width.

View attachment 434814

View attachment 434815

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.

 

[TexasTJ2004]

What is the dana 30 doing wrong that you need to upgrade?

I am not against the wagoneer swap but I would recommend you pencil out the cost before you pull the trigger. In my neck of the woods a worn out Wagoneer dana 44 is $500 up. Then add in brackets, labor etx.

I have Dana 30 HP with Chromoly shafts (real 4340 chromoly steel from Carbon offload, not the fake 1541H, which is actually not chromoly per definition), Yukon Manual hubs, Yukon Grizzly Locker and 4.56 gears. Only missing feature is Black Magic Brake pads, sleeves, truss and C-gussets. Othen then that it is close to perfection.
Bracket truss/swap kit for wagoneer axle is 400$. Labor I plan (or hope) to do myself.

 

[Wildman]

Small bearing spindles with Ford Rotors was in order to switch to JK style 5x5 bolt pattern?
Did you stick to OEM brake caliper and pads?

No OLD school Jeep 5x5.5 BP. And my rear axle had dual drilled axle shafts with 5x4.5 & 5x5.5.

 

[TexasTJ2004]

No OLD school Jeep 5x5.5 BP. And my rear axle had dual drilled axle shafts with 5x4.5 & 5x5.5.

yeah, you are right. I forgot the CJs.

 

[Wildman]

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.

I narrowed mine to Waggy width so I could use off the shelf axle shafts. I linked my writeup in my first reply to you. I used a Rubicon Express bracket kit as it was the only one available at the time. But the same bracket kit that would fit the Waggy axle will fir the HP44. You really do not need a truss.

 

[TexasTJ2004]

I narrowed mine to Waggy width so I could use off the shelf axle shafts. I linked my writeup in my first reply to you. I used a Rubicon Express bracket kit as it was the only one available at the time. But the same bracket kit that would fit the Waggy axle will fir the HP44. You really do not need a truss.

I read through your build thread. First of all, I have to say that it is extremely cool. Second, is that I don't trust my fabrication skills to this level.
The reason I thought about the truss kit was that I did not find anything else - - https://rubiconexpress.com/Fabricat...aspx?t_c=86&t_s=527&t_pt=10373&t_pn=R/ERE9969 - this is the only rubicon express bracket kit, but it seems to be for JK diameter (2.5 inches, when Wagoneer dana 44 is 2.75 inches). Do I miss something and Rubicon express actually has a bracket kit for Wagoneer 2.75 inch tubes?

 

[PNW_LJ]

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.

Good little writeup here, and this is something I bet many 42RLE owners run into. If I hadn’t come across a steal on a TJ 44, I would’ve most likely been going the HP30 route and compromising w/ 5.13s.

One thing to add, an advantage for the low pinion 44 is the ability to put 5.89 gears, which I think would be pretty awesome to have with 35s. Downside is the increased chances of vibes, but the chances are 50/50 even with 5.38s.

 

[TexasTJ2004]

He wants the option of 5.38 gears.

The issue is that with my 42RLE, I need 5.13 gears just to match the same final 70MPH RPM as TJR would have with 6 speed. For anything beyond 33s, 5.38 with 42RLE seems to be a must for me

 

[TexasTJ2004]

Good little writeup here, and this is something I bet many 42RLE owners run into. If I hadn’t come across a steal on a TJ 44, I would’ve most likely been going the HP30 route and compromising w/ 5.13s.

One thing to add, an advantage for the low pinion 44 is the ability to put 5.89 gears, which I think would be pretty awesome to have with 35s. Downside is the increased chances of vibes, but the chances are 50/50 even with 5.38s.

Even with TJR44 front, you are still stuck w/o manual hubs and with weak brakes. If you want to address these, TJR44 is no longer a cheap thing.
Main reason why I am so stuck to manual hubs is that with larger tires, it is almost impossible to maintain both the ideal caster and pinion angles. Higher gears with bad pinion angle will create too much vibration, especially on the front, due to much larger rotating mass. So, manual hubs a must. Prioritize caster for street driveability, and lock the hubs only when wheeling, where driveshaft rotation speed are never high enough to cause any issues.
Yes, 5.89 seems to be attractive for beyond 35 with 42RLE, but I kinda afraid to get vibrations from the rear. I planned to stick to 5.38 at most.

 

[PNW_LJ]

Even with TJR44 front, you are still stuck w/o manual hubs and with weak brakes. If you want to address these, TJR44 is no longer a cheap thing.

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.

Main reason why I am so stuck to manual hubs is that with larger tires, it is almost impossible to maintain both the ideal caster and pinion angles. Higher gears with bad pinion angle will create too much vibration, especially on the front, due to much larger rotating mass. So, manual hubs a must. Prioritize caster for street driveability, and lock the hubs only when wheeling, where driveshaft rotation speed are never high enough to cause any issues.
Yes, 5.89 seems to be attractive for beyond 35 with 42RLE, but I kinda afraid to get vibrations from the rear. I planned to stick to 5.38 at most.

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..

 

[Wildman]

I read through your build thread. First of all, I have to say that it is extremely cool. Second, is that I don't trust my fabrication skills to this level.
The reason I thought about the truss kit was that I did not find anything else - - https://rubiconexpress.com/Fabrication-Tools/Rubicon-Express-Rear-Axle-Bracket-Kit-RE9969.aspx?t_c=86&t_s=527&t_pt=10373&t_pn=R/ERE9969 - this is the only rubicon express bracket kit, but it seems to be for JK diameter (2.5 inches, when Wagoneer dana 44 is 2.75 inches). Do I miss something and Rubicon express actually has a bracket kit for Wagoneer 2.75 inch tubes?

This is the kit I used. The brackets fit the axle tubes fine & if I remember correctly I think they were made for a 3" tube but it was a long time ago.

Rubicon Express Front Axle Bracket Kit - RE9968​

Stinky Fab Bracket kit


Barnes 4WD makes a Waggy truss kit.