i need some advice. I own a 97 tj sahara with 4 inch suspension lift, one inch body lift. i run 35's. it struggles to go up a hill but on flat surface it runs ok.

i need to make it more off road worthy. i want to do a gear swap and add lockers also possibly a dana 44 rear,

my question is what is best way to do this? a complete new or used dana 44 rear?

Also what about the front axle.

thanks for any help

I'm assuming you have a D35 in the rear?

First of all finding a D44 in good shape is going to be difficult at best, they get scooped up quickly, second to by new is going to be very expensive especially if you have the disc brake optioned installed.

My suggestion and this is what I did and very little cost was to go to a salvage yard and purchased a Ford 8.8 rear out of a 98 or newer Ford Explorer,  the axle width is only 5/8" shorter then the Dana has larger tubes then the 44 and larger axles as well and in my opinion just as strong or stronger then the D44, and has disc brakes already installed.

I got mine out of a 2000 with 23k miles on it and it only cost me $200.00

Then all you need to do is grind off the OEM spring perches and weld new perches on the axle tube, not very difficult and there are several sources to purchase the new perches, run new brakes lines and thats pretty much it.

I'm running 3:73 gears to match the stock 3:73 up front and an auto and it's been great. The 3:73's with the auto work just fine and I haven't had any problems going over the same things the the guys with the Dana 60's and 4:10 gears go over and I have the added bonus of a little better gas mileage on the road.

If you want to go that route write me and I'll give ya the the site that explains in detail how to do the swap and where to buy the perches.

Total cost of my swap was $200.00 for the Ford 8.8, $200.00 for the new perches and $75.00 for a new proportioning valve. So for $475.00 and a friends time in welding I have an axle that is just as good as the D44 and it didn't cost me a small fortune.

Good luck,

Bill

Bill, what did you use to replace the front or have you. could you email me the web. sounds like a good replacement for the d35. thanks KC

kc1267@aol.com

Hey KC,

Just sent you the site for the 8.8 swap via AOL addy.

I didn't replace the front D30, so far it has held up very well, I think the D30 gets a bad rap at times. I've been running 35x12.50 MTR's  and a locker up front since I modified it. It now has almost 130,000 miles on it and it hasn't failed yet, but like all things if you try hard enough you'll break something. 

Most times it's not about power it's about finesse, you just have to use your head more then the throttle.  If however you plan on doing some real hardcore rock crawling I'd go for the D44 or D60 up front, but again it's expensive and I would say that for all but the most severe rock crawling I'd stick with the D30 up front.

Good luck, let me know how ya make out.

Bill

Bill,

Thanks for the email. It gives me something else to add to the todo list.

KC

If you can't find the Explorer, the Ford Ranger equipped with the 4.0 also has the 8.8 from '90 and up. My '90 did not hav the disc brakes though, it did have limited slip TRAK-lok though. Happy trails ,TJmak    

Is there anyway u could send me that link as well. i wanna swap my rear axle and that sounds like a great, easy way to go.