Novak Conversions Jeep Wrangler TJ radiator

Decision time on my LJ build

Don't get a RJ60 narrower than 63.5". Otherwise you'll be buying a new axle for 37s either way.
 
I'm now at a point where a decision needs to be made on what do do about the rear. The Jeep is a 2004 LJ, with a stock LJ 3.73 disc brake rear. While I say the maximum tire size I see is 35, I do believe there could come a point where 37s might find there way onto the Jeep. While this is a remote possibility anytime soon, the fact that I'm thinking it tells me to plan accordingly.

With that remote possibility, I don't want to waste money. This leads me to the decision that needs to be made. The way I see it there are two paths to take:

- Option 1. Buy an Eaton E locker and install that along with 5.38 gears (The front has a Rubicon 44 that I just installed) in my current rear. Then, if I did decide to go 37s in the future, I'd have to sell it and upgrade later.
- Option 2. Purchase a complete Currie HP Dana 60 now, with E-Locker and 5.38s

The cost difference between the two is significant. With Option 1, I'm looking at roughly $2000 - $2200, which includes someone else doing the re-gear for me. With Option 2, I'm looking at $5800, so that's a $3600 delta. For that difference, I get a much stronger, even with the semi-float design, rear that could hold up to a 37" tire and I don't sacrifice ground clearance.

The only things making me hesitate are the stock 60.5 width and the fact that I'd also need to factor in a rear AntiRock to get the most travel at full droop. The stock 60.5" width is really the big factor making me pause. Common sense says if I'm going to go to the trouble of buying and installing a Dana 60, it should be a minimum of 63.5' width. Thoughts?

There is almost no penalty for running a 1-2" wheel spacer on a rear axle to get some additional width. We do it all the time and then have a front axle built to the correct width for the tire size. There is a pretty big group of folks who bought that piece of shit G2 HP rear Currie 60 housing set up at TJ width so they can slap their 35 spline Set 10 Dana 44 shafts in it and call it a 60. It is too narrow for 37's but a set of wheel spacers fixes that right up. You can't do the same to the front unless you want fucked up steering.
 
If the likelihood of going to 37s is remote I'd stick with the current axle and regear and add the locker. If you do end up going to 37s in the future then you can cross that bridge when you come to it. Probably won't be a popular view around here, but I think it is the logical decision. Sounds like you might get a fair chunk of that cost back, which would mean little penalty not going to the 60 now.
 
I'm going to reiterate my first post in this thread...and maybe add some color. FWIW, none of this is meant to be judgemental in anyway. Just hoping to present another viewpoint from an outsider, since we all know that sometimes we can be too close to something to be objective.

There was a pretty nice LJ in your stable a couple years ago. It wasn't perfect, but it was pretty nice. That was sold in the interest of going smaller (and possibly some personal reasons, no need to go into that).

The TJ was then built smaller. That was first on 31's, now 33's. Again, no judgement, just an observation. In the meantime, the LJ was purchased and was going to stay stock (or maybe stock +). Wheeling duty was to be handled by the small, nimble TJ.

Now, you're unhappy with the TJ, or wanting to pass it on. However you've come to the decision to build the LJ, you've stated its a full build now. Great! But...you're already thinking about 37's in the future. You've HAD an LJ on 35's...so you know what that is (and I suspect its why 37's are in your head).

My opinion is build it for 37's now. I believe you'll end up there eventually. Also, don't discredit those that you wheel with that are running broncos on 37's and 44's...There is an answer there. The "right" 44 can be built and work for 37's (as long as you don't want 40's, later, LOL)
 
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My opinion is build it for 37's now. I believe you'll end up there eventually. Also, don't discredit those that you wheel with that are running broncos on 37's and 44's...There is an answer there. The "right" 44 can be built and work for 37's (as long as you don't want 40's, later, LOL)

Agreed .. ask yourself if you really want 37s, and if the answer is yes, plan and budget for it and be cognizant of the (significant) time, effort and money a proper 37s build will take. Pay attention to the wheelbase/frame height/tire size balance that knowledgeable folks like Blaine talk about and make sure all the nuances are well understood. There are 50 ways to do it incorrectly and few ways to get it fully right.
 
@Irun,

My opinion is classic advice. Decide on your final tire size and build for it. That’s the best way not to “waste” money as you put it.

This is coming from someone who keeps building bigger (31’s, 33’s, 35’s…….)

Part of it is we are project people, so all is not lost when you build incrementally, and it’s a learning process. You’ve already built everything from stock to 35’s, so you can go straight to a 37’s build without the incremental learning process up to 35’s. Go get it!
 
Now, you're unhappy with the TJ, or wanting to pass it on. However you've come to the decision to build the LJ, you've stated its a full build now. Great! But...you're already thinking about 37's in the future. You've HAD an LJ on 35's...so you know what that is (and I suspect its why 37's are in your head).
I'll be crystal clear about one thing here. I'm not unhappy at all with the TJ. In fact, it's the complete opposite. The TJ has exceeded all my expectations. It drives fantastic, performs flawlessly off road, and takes me almost anywhere I'd want to go. Being very honest, it is my favorite. Especially given all the work and thought I've put into it. The only reason it's going to a new home is complete a promise I made to my son. This is a multi-year story that I won't go into here. A story that could have had a much darker ending.

As for the LJ, sometimes in your life things don't go as you think they will. While the TJ is my favorite, having an LJ is a much better fit for my personal circumstances. Honestly, I only started this thread because I genuinely want to hear what others have to say. Frankly, I'm struggling with the basic decision of what do do about the rear. Realistically, I don't see myself going 37s on the LJ, but with all the wasted money I've spent on mods over the years, it's more about your post #8 "future proofing" comment. I don't know what I don't know.
 
...Realistically, I don't see myself going 37s on the LJ, but with all the wasted money I've spent on mods over the years, it's more about your post #8 "future proofing" comment. I don't know what I don't know.

But if you do not see yourself going to 37s isn't the most likely way you will waste money by spending it on an axle you don't need?

I'll ask another question to try and help you frame your thinking. Do you think your Dana 44 front is up to 37s. There seem to be differing views expressed in this thread, but what do you think? If your answer is you do not think the Dana 44 front is up to 37s, what made you comfortable swapping that axle into your LJ? And, if it is about future proofing should you not abandon the Dana 44 front and future proof the front axle as well?
 
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But if you do not see yourself going to 37s isn't the most likely way you will waste money by spending it on an axle you don't need?

I'll ask another question to try and help you frame your thinking. Do you think your Dana 44 front is up to 37s. There seem to be differing views expressed in this thread, but what do you think? If your answer is you do not think the Dana 44 front is up to 37s, what made you comfortable swapping that axle into your LJ? And, if it is about future proofing should you not abandon the Dana 44 front and future proof the front axle as well?
There is a significant difference between the front and rear. For the front, I already have the 5.38 gears and install kit to make that happen. For what I paid for the 44 front, which came with Revolution gears and install kit, I could easily sell it and clear a profit, if I sold it in the future. Plus, I already have a spare Rubicon front locker, NOS diaphragm, and a set of brand new locker pumps. The rear is not from a Rubicon, which means I need to install a locker and rebuild kit. The locker alone is roughly $1100.

Maybe my thought process is flawed, which I'm open to hearing about. If I go the route of the rear Currie 60, my thinking was I'm losing about 1" of ground clearance, but I'm gaining:

- Set20 outer bearings;
- 1.50" 35 spline axle shafts and locker;
- Larger pinion bearing (HM 803146);
- 1350 axle side U joint (still limited to a 1330 on the transfer case side);
- Built in replaceable differential slider;
- Stronger axle tubes and center section, and;
- An additional 2" of clearance at the pinion.

With Blaine's comment about spacers, I could add up to 2" on either side, which puts me within an inch of a future 65.5" Dana 60, if that happened. If I bought the Currie 60 and didn't go 37s, all I'm out is a few $ and a little clearnace, but I'd have a rear that would handle whatever I'd throw at it on 35s.

All that said, I am trying to keep an open mind here. If the 44 is the way to go, so be it. If there's a better, but more expensive alternative, I'd like to at least know it's there and consider it.
 
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There is almost no penalty for running a 1-2" wheel spacer on a rear axle to get some additional width. We do it all the time and then have a front axle built to the correct width for the tire size. There is a pretty big group of folks who bought that piece of shit G2 HP rear Currie 60 housing set up at TJ width so they can slap their 35 spline Set 10 Dana 44 shafts in it and call it a 60. It is too narrow for 37's but a set of wheel spacers fixes that right up. You can't do the same to the front unless you want fucked up steering.

I had to look up the G2 HP 60. It certainly makes you wonder why someone would buy a 60 housing, but then build it with Dana 44 bearings. There must be some logic there, but I'm missing it.
 
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I had to look up the G2 HP 60. It certainly makes you wonder why someone would buy a 60 housing, but then build it with Dana 44 bearings. There must be some logic there, but I'm missing it.
The logic was basic. G2 had their own supply of lockers, gear sets, and axle shafts in 35 spline for the Dana 44. All cheaper than Currie could supply them for as a complete axle assembly. All they needed was a housing to stick it all in and they convinced Currie to do them. They came without the welded on bosses to bolt Currie's truss onto and compounding that error for the sake of economy, they got them to drill and tap the vent fitting right where that boss would weld. That means if you wanted to use the bolt on truss, you had fill the hole with weld and move it.

FYI- the rear 44's that have been mentioned as suitable for being built up to handle 37's use the same Set 10 bearings. If that's a deal breaker, then you are looking at some other axle.
 
Novak Conversions Jeep Wrangler TJ radiator