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Unread 01-03-2010, 09:13 PM   #1
Nick2000wj
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axle swap in wj

Im looking to upgrade the dana 35 out of my 6 cylinder wj...i was thinking of swapping out my axles with v8 wj axles. i am just wondering if the dana 44a out of a wj bolts right in or if i am going to run into problems.

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Unread 01-03-2010, 09:14 PM   #2
g-off70
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as long it is a wj 44a, it is a direct bolt in
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Unread 01-03-2010, 09:16 PM   #3
Nick2000wj
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thanks. also just wondering if there were any years where the v8 wj came with a hp 30 in the front?
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Unread 01-03-2010, 09:30 PM   #4
Wheelin98TJ
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The front axle was low pinion across all the model years for the WJ.
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Unread 01-03-2010, 09:48 PM   #5
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Quote:
Originally Posted by Nick2000wj View Post
Im looking to upgrade the dana 35 out of my 6 cylinder wj...i was thinking of swapping out my axles with v8 wj axles. i am just wondering if the dana 44a out of a wj bolts right in or if i am going to run into problems.
It will be a bolt in if it has the same 3.55 gear ratio. Most likely it will have 3.73 gears, and then you will have to either regear the front axle, or swap that as well. Your gear ratios must match front and rear.
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Unread 01-03-2010, 10:07 PM   #6
Wheelin98TJ
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I'm not sure its worth the effort because of the lack of aftermarket support for the 44a.

The slightly lower 3.73 gear ratio would be nice, but its not much of a change from 3.55 and its still a little high for 32" or larger tires.

Are there any upgraded axle shafts available for the WJ D35?
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Unread 01-03-2010, 10:14 PM   #7
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I did the full swap after grenading my diffs last year. The 44a will bolt right in, no issues except gear ratio and the drive shaft. The pinion neck on the 44a is longer than that of the 35, therefore your driveshaft will be a bit too long. Just get it cut to size after the axle is in.

wheelintj - it isn't the aftermarket support that people look at for the 44a swap, it's the all around stronger axle (minus the aluminum pumpkin). Truss the 44a and you're good to go.
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Unread 01-03-2010, 10:30 PM   #8
Wheelin98TJ
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Quote:
Originally Posted by perfectcircle View Post
wheelintj - it isn't the aftermarket support that people look at for the 44a swap, it's the all around stronger axle (minus the aluminum pumpkin). Truss the 44a and you're good to go.
The strength increase with the 44a is certainly a benefit, but the lack of aftermarket support is a pretty big downfall.

If you could add 30 spline chrome moly axle shafts and a 30 spline locker to a WJ D35, I think that is a route definitely worth considering.

The 30 spline D35 chrome moly axle shafts are stronger than a stock D44a axle shaft.

If you do not want a locker, I don't think an axle upgrade is necessary.
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Unread 01-04-2010, 12:43 AM   #9
ratmonkey
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All the WJ axles are red headed step children. Axle shafts need to be custom ordered if you want high strength. Nothing off the shelf for increased spline count.

The 44a is still better all around than a WJ d35, even with only one locker and LSD available.
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Unread 01-04-2010, 07:13 AM   #10
Wheelin98TJ
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Quote:
Originally Posted by ratmonkey View Post
All the WJ axles are red headed step children. Axle shafts need to be custom ordered if you want high strength. Nothing off the shelf for increased spline count.

The 44a is still better all around than a WJ d35, even with only one locker and LSD available.
I agree that the 44a is a better axle, but I would say its only slightly better.

I'm just not sure its worth the effort and cost, especially if you also have to do the front axle or regear it.
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Unread 01-04-2010, 10:33 AM   #11
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Like said the 44a (44HD)is a direct swap but you have to make sure the front gears match the rear gears. Also you most likely have to shorten your rear drive shaft or get a new one. The 44a has some week points but is stronger than a regular d44, its a great axle and more comparable to a d60 thats why its also called a 44HD, if you truss and skid it you eliminate the week points and will have yourself a great swap.

Some specs to compair:

Dana 35
Ring Gear Diameter = 7.56"
Pinion Shaft Diameter = 1.406"
Ring Gear Bolt Count = 8
Pinion Spline = 26
Cover Bolts = 10
Axle Shafts = 27 Spline
Axle Shaft Diameter =
Axle Housing Diameter = 2.625"
Carrier Break = 3.31 and down; 3.55 and up

Dana 44A
Ring Gear Diameter = 8.5"
Pinion Shaft Diameter = 1.625"
Ring Gear Bolt Count = 10
Pinion Spline = 29
Cover Bolt Count = 10
Axle Shafts = 30 Spline
Axle Shaft Diameter = 1.25"
Axle Housing Diameter = not sure
Carrier Break = 3.55 and down; 3.73 and up

Dana 44 Iron
Ring Gear Diameter = 8.5"
Pinion Shaft Diameter = 1.376"
Ring Gear Bolt Count = 10
Pinion Spline = 26
Cover Bolt Count = 10
Axle Shafts = 30 Spline
Axle Shaft Diameter = 1.19"
Axle Housing Diameter = not sure
Carrier break = 3.73 and down; 3.92 and up

Dana 60
Ring Gear Diameter = 9.75"
Pinion Shaft Diameter = 1.626"
Ring Gear Bolt Count = 12
Pinion Spline = 29
Cover Bolt Count = 10
Axle Shafts = 30 (3/4 ton) 35 (1 ton)
Axle Shaft Diameter = not sure
Axle Housing Diameter = not sure
Carrier Break = not sure



This would solve the week spots on the 44a, click on dana 44a truss/skid: Products
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Last edited by WJ04; 01-04-2010 at 10:44 AM..
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Unread 01-04-2010, 10:57 AM   #12
ArloGuthroJeep
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It'll bolt right over, but the drive shaft may be a bit too long (mine was 1" too long).
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Unread 01-04-2010, 11:28 AM   #13
Wheelin98TJ
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Quote:
Originally Posted by WJ04 View Post
Like said the 44a (44HD)is a direct swap but you have to make sure the front gears match the rear gears. Also you most likely have to shorten your rear drive shaft or get a new one. The 44a has some week points but is stronger than a regular d44, its a great axle and more comparable to a d60 thats why its also called a 44HD, if you truss and skid it you eliminate the week points and will have yourself a great swap.

Some specs to compair:

Dana 35
Ring Gear Diameter = 7.56"
Pinion Shaft Diameter = 1.406"
Ring Gear Bolt Count = 8
Pinion Spline = 26
Cover Bolts = 10
Axle Shafts = 27 Spline
Axle Shaft Diameter =
Axle Housing Diameter = 2.625"
Carrier Break = 3.31 and down; 3.55 and up

Dana 44A
Ring Gear Diameter = 8.5"
Pinion Shaft Diameter = 1.625"
Ring Gear Bolt Count = 10
Pinion Spline = 29
Cover Bolt Count = 10
Axle Shafts = 30 Spline
Axle Shaft Diameter = 1.25"
Axle Housing Diameter = not sure
Carrier Break = 3.55 and down; 3.73 and up

Dana 44 Iron
Ring Gear Diameter = 8.5"
Pinion Shaft Diameter = 1.376"
Ring Gear Bolt Count = 10
Pinion Spline = 26
Cover Bolt Count = 10
Axle Shafts = 30 Spline
Axle Shaft Diameter = 1.19"
Axle Housing Diameter = not sure
Carrier break = 3.73 and down; 3.92 and up

Dana 60
Ring Gear Diameter = 9.75"
Pinion Shaft Diameter = 1.626"
Ring Gear Bolt Count = 12
Pinion Spline = 29
Cover Bolt Count = 10
Axle Shafts = 30 (3/4 ton) 35 (1 ton)
Axle Shaft Diameter = not sure
Axle Housing Diameter = not sure
Carrier Break = not sure



This would solve the week spots on the 44a, click on dana 44a truss/skid: Products

The 44a and the iron 44 both have 30 spline 1.30" axle shafts.

The only place the 44a is larger than the iron 44 is the pinion shaft diameter/spline count which is an uncommon failure point for both the iron 44 and the D35.
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Unread 01-04-2010, 03:30 PM   #14
ratmonkey
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an iron 44 swap will require welding on brackets(the a-arm attachment will need to be on a truss) and width and bolt pattern changes going into a wj. plus you will most likely lose the rear swaybar which is the most important one on a wj.

the 44a is the most cost effective swap if you want a stronger axle than a d35 in a wj. higher spline chromo shafts would need to be custom made and are likely to be more expensive than an iron 44 swap.
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