XJ Dana 44 swap into TJ

[chrispej]

found a pair of xj axles (hp Dana 30/Dana 44), geared 4.11, with pneumatic lockers installed, and on board compressor included in the bundle. figured itd be a steal seeing as the Dana 30 is plug n play, but i found out that the Dana 44 is set up for leaf springs.

my idea was rather than welding, would it be more simple to just swap out whats inside the purchase Dana 44 into my current Dana 44? that way itd mount up just fine, or is messing with gears just too tough, simpler maybe to just weld

cheers for any help, based in australia aswell, had a look for welding bracket kits as mentioned on other threads (artec ind/tmr customs) but no luck

 

[chrispej]

also, would the high pinion axle improve my driveline angle when lifting? as opposed to the regular Dana 30

 

[JEEPSTEVENANAIMO]

i dont know much abotu this but i do know the high pinion 30 is better than the low pinion.

 

[hear]

People around here are definitely getting more bold with doing their own gears, but I would think the effort/risk of updating & swapping in the donor axle would be a chunk less effort than to do the re-gear job. Plus if you're going to the effort to do a re-gear, you at least will want a new master install kit (bearings, seals, shims), but you're still putting in used gears. And you may need to buy some specialty tools to do the regear, although you may not be able to do the welding yourself either. ¯\_(ツ)_/¯

Others here will probably have a more informed opinion, ymmv.

 

[tworley]

Setting up used gears isn't worth the hassle. The gears already have a hardened wear pattern that will no longer match if you swap it over. Meaning you're not going to get the same pattern in the new housing and who knows how long the gears will survive. Not to say it can't be done though...

The HPD30 will bolt right up to your TJ and everything from your current Dana 30 will swap right over. As to the 44, you can buy axle brackets. I bought my bracket set from Rubicon Express IIRC. They are 3/16" and consisted of spring perches, control arm mounts, sway bar mount and a trackbar bracket that fit a 3" axle tube. Though this was years ago (almost 10?), not sure if they still make them or not. Barnes has a lot of fabrication parts/mounts you can buy. Might be worth looking there, too.

 

[06lj]

If the axles are cheap they might be worth the parts. Without more information it would be hard to tell. The XJ 44 is not a simple swap and I don't see how it would be worth the effort since you already have a Dana 44. The locker and axle shafts would really be the only things of value. If they are in good condition and the price is right then it might be worth it. The HP Dana 30 is a direct swap and is a bit of an upgrade if you need a new front axle or are already planning to regear. Otherwise it really isn't worth it. Around here the HP Dana 30's run around $100. Swapping used gears is not something that is recommended. It can be done but the likelihood of getting the gears set precisely as they were is basically impossible. I put a HP Dana 30 in my Jeep. I only did this because the XJ Dana 30's are cheaper than the TJ Dana 30's. I was learning to do my own gears and I used the extra axle as an experiment. I figured if I completely botched the job I wouldn't have been stuck with a Jeep with broken gears. If you are capable of differential work and/or are motivated to learn, then used parts can be a deal. If you plan to take it to a shop I would check if they will even touch used parts before investing any money.

 

[chrispej]

thanks for all your help, so ill avoid the regear and may look into welding. price would be around $750aud for both axles and all the goodies included. hard to source parts here on the cheap since the jeep is an import, and no one really stocks for petrol 4wd here, so im kinda hoping to get by on the cheap here.

 

[chrispej]

Setting up used gears isn't worth the hassle. The gears already have a hardened wear pattern that will no longer match if you swap it over. Meaning you're not going to get the same pattern in the new housing and who knows how long the gears will survive. Not to say it can't be done though...

The HPD30 will bolt right up to your TJ and everything from your current Dana 30 will swap right over. As to the 44, you can buy axle brackets. I bought my bracket set from Rubicon Express IIRC. They are 3/16" and consisted of spring perches, control arm mounts, sway bar mount and a trackbar bracket that fit a 3" axle tube. Though this was years ago (almost 10?), not sure if they still make them or not. Barnes has a lot of fabrication parts/mounts you can buy. Might be worth looking there, too.

looks like that rubicon express bracket kit is still available on ebay you wouldnt know the specific part number or any identifying traits aside from that 3/16 number u threw out?

 

[tworley]

looks like that rubicon express bracket kit is still available on ebay you wouldnt know the specific part number or any identifying traits aside from that 3/16 number u threw out?

Quick search and looks like RE9969
https://rubiconexpress.com/Fabricat...aspx?t_c=86&t_s=527&t_pt=10373&t_pn=R/ERE9969

 

[Woodrow]

I can’t resist jumping in here because its a fun question. Setting up gears and welding both require a specific skill set and tools.
Option 1: put the air locker in your current axle with the current or new shafts (whichever is better or necessary). If I was going this route, I’d buy new gears and a master install kit. I’m guessing that would be $5-600 if you can do the work. For myself, this is the easiest and likely cheapest choice.
Option 2: Cut the spring perches, etc off the XJ axle, weld on new brackets and install. The additional question here is: What brackets? Now I know you are looking for cheap so maybe you could cut the brackets off your old axle and re-use? (that would be tough, I think). If it were me and I’m cutting and welding anyway, it would be hard to pass up the opportunity to go with a triangulated 4-link…

 

[chrispej]

I can’t resist jumping in here because its a fun question. Setting up gears and welding both require a specific skill set and tools.
Option 1: put the air locker in your current axle with the current or new shafts (whichever is better or necessary). If I was going this route, I’d buy new gears and a master install kit. I’m guessing that would be $5-600 if you can do the work. For myself, this is the easiest and likely cheapest choice.
Option 2: Cut the spring perches, etc off the XJ axle, weld on new brackets and install. The additional question here is: What brackets? Now I know you are looking for cheap so maybe you could cut the brackets off your old axle and re-use? (that would be tough, I think). If it were me and I’m cutting and welding anyway, it would be hard to pass up the opportunity to go with a triangulated 4-link

whats a triangulated 4-link?

it seems option 1 is the most expensive for me 1500usd for locker, compressor, and gears, vs 900usd for the same installed + welding brackets from ur neighbours to the north. n surely welding aint too hard, i got a 2 or 3 brain cells to scrape together, ought to do it

i do like your suggestion to cut and reuse could be a good move as a bit of a miser.

 

[Woodrow]

This is a trangulated 4 link (the rear Savvy mid-arm in this case):

Here is an example in the wild:

The set up improves the geometry of a lifted suspension, if designed well. That can do things like reduce wheel hop when climbing. And because of the triangular structure, side to side axle motion is controlled without the use of a track bar.

These set ups can be expensive and a lot of work to install so probably not what you are looking for now, but you asked so there you go.

 

[chrispej]

This is a trangulated 4 link (the rear Savvy mid-arm in this case):
View attachment 566615
Here is an example in the wild:
View attachment 566614
The set up improves the geometry of a lifted suspension, if designed well. That can do things like reduce wheel hop when climbing. And because of the triangular structure, side to side axle motion is controlled without the use of a track bar.

These set ups can be expensive and a lot of work to install so probably not what you are looking for now, but you asked so there you go.

hahah wow, yeah i think thats a bit outta sight for me, still green with all this, just tryna build a capable forever rig. once the dilla starts coming in ill get her going. thank you so much for all your help again tho, appreciate people like yourself, lot of snarky people on here