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Axle Information Writeup/Thread

33K views 28 replies 13 participants last post by  chupacabrah  
#1 · (Edited)
I've been seeing a lot of questions regarding axle strength, U-joints, tire size, etc etc. I found that theres a lot of info out there, but it can be hard to put it all together and sometimes hard to find. So, I've taken a little reasearch, a nice artical provided by JP Magazine and a few websites to help out a bit. Here is some axle information: (Note, most Dana axle spec information is given for Jeep application axles, spec information for other manufacturers may vary [i.e. Chevy axle width, stock gearing, etc])

FRONT AXLES
D27 Front Axle:
Full Floating
Vehicles: '66-'71 CJ-5 and CJ-6; '63-'70 Wagoneer; '67-'71 C-101 Jeepster
Ring Gear: 7.2"
Stock Gearing:
Axleshaft Spline: 10
Axleshaft Diameter: 1.13"
Axle Joint: Spicer 260X
Knuckle: Closed
Brakes: Drum 10" 11"
Weakness: Weak axle for upgrades, low spline count, weak carrier
Width: 51" (CJ and Jeepster), 57.5" (Wagoneer)
Wheel Bolt: 5x5.5"
Max Recommended Tire Size: 31"

D30 Front Axle:
Full/Semi Floating
Vehicles: From '72 CJ-5, CJ-6, CJ-7, CJ-8, YJ, TJ, XJ, ZJ, C104, WJ
Ring Gear: 7.125", 7.33" (TJ/WJ Only)
Stock Gearing: 3.07, 3.54 (3.55), 3.73, 4.10 (4.11)
Axleshaft Spline: 27
Axleshaft Diameter: 1.16", 1.193" (TJ/WJ Only)
Axle Joint: Spicer 260X (pre '95.5), Spicer 297/760X (post '95.5), CV & 760 U-Joint (TJ/WJ)
Knuckle: Open
Brakes: Drum 11" (pre '76), Disc (post '76)
Weakness: 260X U-joint; YJ Vacuum motor fails; standard CV problems
Width: 51" ('72-'75 CJ, C-104), 53" ('76-'81 CJ), 56" ('82-'86 CJ), 60.5" (TJ, YJ, XJ, WJ)
Wheel Bolt: 5x5.5" (CJ/C-104), 5x4.5" (others)
Max Recommended Tire Size: 35"

AAM 790 Front Axle
Semi Floating
Vehicles: '05 and later WK
Ring Gear: 7.87"
Stock Gearing:
Axleshaft Spline:
Axleshaft Diameter:
Axleshaft Joint: CV
Knuckle: Open
Brakes: Disc
Weakness: Limited modification ability, small ring gear
Width:
Wheel Bolt:
Max Recommended Tire Size: 32"

D44 Front Axle:
Full/Semi Floating
Vehicles: '57-'65 FC-170; '63-'70 Gladiator; '67-'79 1/2 & 3/4 Ton Ford Pickups; '71-'87 J-Series; '71-'91 Wagoneer; '72-'93 1/2 & 3/4 Ton Dodge Pickups; '73-'79 1/2 & 3/4 Ton Chevy Pickups; '74-'83 Cherokee; '03-'06 Rubicon
Ring Gear: 8.5"
Stock Gearing: Many
Axleshaft Spline: 19 (pre '71), 30 (post '71)
Axleshaft Diameter: 1.25" (19 spline), 1.31" (30 spline)
Axle Joint: Spicer 206X (pre '73), Spicer 297/760C (post '73)
Knuckle: Closed (pre '73), Open (post '73)
Brakes: Drum 11" (pre '73), Disc (post '73)
Weakness: 260X and 19 spline axleshafts
Width: 63" (FC-170), 57.5" ('71-'73 Wagoneer), 59" ('74 and later Wagoneer), 65.5" (J-Series), 60.5" (Rubicon), Full Width (Ford, Dodge, Chevy)
Wheel Bolt: (Varies)
Max Recommended Tire Size: 37"

D60 Front Axle:
Full Floating
Vehicles: '67-'69 Kaiser M-715; '72-'93 3/4 & 1 Ton Dodge Pickups; '74-'77 3/4 Ton Ford Pickups; '77-'87 3/4 & 1 Ton Chevy Pickups; '78-'79 1 Ton Ford Pickups
Ring Gear: 9.75"
Stock Gearing: 4.10, 4.56
Axleshaft Spline: 30
Axleshaft Diameter: 1.31"
Axle Joint: Unknown Spicer
Knuckle: Closed
Brakes: Drum 13"
Weakness: Metallurgically axleshafts inferior to modern metals
Width: 72.5" (M-715), Full Width (Ford, Dodge and Chevy)
Wheel Bolt: 6x8.25"
Max Recommended Tire Size: 42"

REAR AXLES
D35 Rear Axle:
Semi-floating ('85-'89), C-clip ('90 and later)
Vehicles: Most XJ; YJ; TJ (except Rubicon); ZJ; some WJ
Ring Gear: 7.562"
Stock Gearing: 3.07, 3.54 (3.55), 3.73, 4.10 (4.11)
Axleshaft Spline: 27
Axleshaft Diameter: 1.13"
Brakes: Drum 11"; Disc (later ZJ/WJ)
Weakness: Weak carrier & axleshafts
Width: 60.5"
Wheel Bolt: 5x4.5"
Max Recommended Tire Size: 33"

D44 Rear Axle:
Semi Floating
Vehicles (here we go…*long breath*): '49-'65 6cyl Willy Wagons; '49.5-'53 CJ-3A; '53-'68 CJ-3B; '50-'52 M-38; '52-'57 M-38A1; '53-'57 M-170; '55-'75 CJ-5 & CJ-6; '85.5-'86 CJ-7; '58-'65 FC-150; '57-'65 FC-170; '63-'70 Wagoneer & Gladiator Pickup; '67-'71 C-101 Jeepster; '72-'73 C-104; '71-'75 Wagoneer & ½-ton J-Series; '74-'83 Cherokee; '87-'91 Grand Wagoneer; Some '86-'92 XJ and MJ; Some '97-'06 TJ; '99-'04 WJ; '96-'98 ZJ
Ring Gear: 8.5", 8.9" (WJ only )
Stock Gearing: Many, including 3.55, 3.73, 4.11
Axleshaft Spline: 10 ('49-'55), 19 ('56-'70.5), 30 ('70.5 and later)
Axleshaft Diameter: 1.193" (WJ/ZJ) 1.25" (10 and 19 Spline), 1.31 (30 Spline)
Brakes: Drum 9", 10", 11"; Disc (Rubicon, ZJ, WJ)
Weakness: 10 & 19 Spline, Some aluminum housings.
Width: 50.5" (up to '75 CJ, FC, C-101, C-104), 54.5" ('85-'86 CJ), 57.5" ('63-'73 Wagoneer), 60.5" (XJ, MJ, TJ, ZJ, WJ), 65.5" (FSJ Cherokee, J-Series)
Wheel Bolt: Varies
Max Recommended Tire Size: 35"

D53 Rear Axle:
Semi Floating
Vehicles: '55-'65 Willys pickup; '63-'69 Gladiator; '57-'65 FC-170
Ring Gear: 9.25"
Stock Gearing:
Axleshaft Spline: 20
Axleshaft Diameter: 1.31"
Brakes: Drum 11"
Weakness: Hard to find parts, low spline
Width: 65.5" (Gladitaor), 63" (Others)
Wheel Bolt: 5x5.5"
Max Recommended Tire Size: 35"

D60 Rear Axle:
Semi/Full Floating
Vehicles: '67-'69 1/2 & 3/4 Ton Ford Pickups; '69-'87 J-2000/J-20; '72-'93 3/4 Ton Dodge Pickups
Ring Gear: 9.75"
Stock Gearing 4.10, 4.56
Axleshaft Spline: 30
Axleshaft Diameter: 1.31"
Brakes: Drum 12"
Weakness:
Width: 65.5" (J-2000/J-20), Full Width (Ford, Dodge & Chevy)
Wheel Bolt: 8x6.5"
Max Recommended Tire Size: 42"

D70 Rear Axle:
Full Floating
Vehicles:'58-'68 FC-170 w/dual rear wheels; '63-'68 J-3000 w/dual rear wheels; '67-'69 M-715; CJ-10; '72-'93 3/4 & 1 Ton Dodge Pickups; '76-'77 3/4 Ton Ford Pickups; '77-'87 1 Ton Chevrolet Pickups; '78-'79 1 Ton Ford Pickups
Ring Gear: 10.5"
Stock Gearing: 4.10, 4.56
Axleshaft Spline: 23, 35
Axleshaft Diameter: 1.5"
Brakes: Drum 13"
Weakness: Poor parts availability
Width: 59" (FC & Pickup), 72" (M-715), Full Width (Ford, Dodge and Chevy)
Wheel Bolt: 6x7.25" (M-715), 8x6.5" (others)
Max Recommended Tire Size: 44"

AMC20 Rear Axle:
Semi Floating
Vehicles: '76-'86 CJ; '76-'91 Wagoneer and J-10
Ring Gear: 8.875"
Stock Gearing: 2.76, 3.07
Axleshaft Spline: 20
Axleshaft Diameter: 1.31"
Brakes: Drum 11"
Weakness: 2 piece axleshafts (CJ only), tubes spin, 20 spline
Width: 50.5" ('76-'81 CJ), 54.5" ('82-'86 CJ), 59" (Wagoneer), 65.5" (J-Series)
Wheel Bolt: 5x5.5" (CJ), 6x5.5" (Wagoneer and J-Series)
Max Recommended Tire Size: 33"-35"

Chrysler 8.25 Rear Axle:
C-clip
Vehicles: '91-'01 XJ
Ring Gear: 8.25"
Stock Gearing: 3.55, 3.73, 4.10
Axleshaft Spline: 27 ('91-'96), 29 ('96-'01)
Axleshaft Diameter: 1.17" (27 spline), 1.21 (29 spline)
Brakes: Drum 11"
Weakness: 27 spline, c-clip
Width: 60.5"
Wheel Bolt: 5x4.5"
Max Recommended Tire Size: 35"

Ford 8.8 Rear Axle
C-clip
Vehicles: Ford Explorer (Prefered Swap, information reflects Explorer only), Ford F-Series , Ford Ranger
Ring Gear: 8.8"
Stock Gearing: 3.08, 3.27, 3.55, 3.73, 4.10
Axleshaft Spline: 28, 31
Axleshaft Diameter: 1.320"
Brakes: Drum ('91-'94), Disc ('95-'01)
Weakness: C-clip, weak carrier
Width: 59.625" to 65.6"
Wheel Bolt: Most 5x4.5"
Max Recommended Tire Size: 40"

AXLE STRENGHTS:
COT - Continuous Output Torque
MOT - Maximum Output Torque

Dana 35 ........................ COT: 870 MOT: 3480
AMC 20 .........................
Chrysler 8.25 .................
Dana 53 ........................
Dana 44 ........................ COT: 1100 MOT: 4460
Ford 8.8 28 spline ........... COT: 1250 MOT: 4600
Ford 8.8 31 spline ........... COT: 1360 MOT: 5100
Dana 60 semifloat ........... COT: 1500 MOT: 5500
Dana 70 ........................
Rockwell 2.5 Ton ............ Industructable

IDENTIFICATION:
Tag Identification:
D30: "30" cast into back of diff casing on top right and left next to diff cover. Tag bolted on diff cover with axle ID and gear ratio.
D35: "35" cast into back of diff casing on top right and left next to diff cover. "C" next to "35" DOES NOT stand for c-clip, but "custom" (unfinished by Spicer). Tag bolted on diff cover with axle ID and gear ratio.
D44: In most cases "44" into back of diff casing on top right and left next to diff cover. Tag bolted on diff cover with axle ID and gear ratio.
D60: Similar looking casing to the D44, except the oil fill plug is elevated to provide more fluid for the larger gears.
Chrysler 8.25: Tag wrapped around passenger side tube with axle ID and gear ratio.
Ford 8.8: See Joe Dillard and T.Dome's writeup linked at the bottom of the page

Differential Cover Identification:
AMC 20: 12 cover bolts, round cover, fill plug not present
D27: 10 cover bolts, oval with straight sides, distinguished ring gear extension, low fill plug
D30: 10 cover bolts (five on top, five on bottom), oval cover w/flat sides, fill plug just below centerline
D35: 10 cover bolts, evenly spaced, oval "dome" shaped cover with low fill plug
D44: 10 cover bolts, hexagon shaped cover with very round edges, fill plug on centerline
D60: 10 cover bolts, hexagon shaped cover, fill plug on centerline
D70: 10 cover bolts, hexagon shaped cover, fill plug on centerline
Chrystler 8.25: 10 cover bolts, oval shaped cover, fill plug just below centerline
Ford 8.8: 10 cover bolts, square with very round edges, fill plug not present on cover

Image


Gear Identification:
If the gears are unidentifiable from the tag or if the tag is missing, there are two methods to find the gear ratio.

1) Spin the tire one full rotation and watch how far the driveshaft rotates. Double the amount the driveshaft rotated, this gives you your gear ratio. Be sure you are spinning the tire forwards.

2) Count ring & pinion gears: Count the number of teeth on the ring and the pinion. Then divide the ring teeth by the pinion teeth to attain the gear ratio.

USEFUL LINKS
Identification information along with applications outside the Jeep family can be found here

Very informational thread by OhioYJ covering the Jeep, GM, Ford and Chrystler axles at cdmfabrication

All the information you could ever need pertaining to the Ford 8.8 by Joe Dillard and T.Dome

More information better encompasing years and qualities of the D60 and Ford 9"

A writeup by Tomb Raider on axle u-joint replacement

Another writeup by OhioYJ also on u-joint replacement

Now there was a ton of typing in there and a lot of numbers, so feel free to correct me if you see a misprint or mislabeled information. Also, if you have any information to add, please let me know and I will go about adding it.
 
#3 ·
theonecsf said:
Good info, thanks.

One question, is the Chrysler 8.25 rear axle easier to install into a YJ than a Ford 8.8?
It requires relitivily the same amount of work. Its slightly cheaper however depending on what year you get, but only about as strong as a D44 (at least the 30 splines). The up-side is you need no adaptors to make the brakes work since it uses the same style brake setup the D35 does, so you save some money there. I was looking into it, but couldn't find a 30 spline in the right ratio, so i passed for the time being.
 
#6 ·
Ratio: Pinion/Ring Combo:
3.08:1 13/40
3.38:1 13/43
3.55:1 13/46
4.10(4.11):1 9/37
I would just explain how the ratios are determined, by dividing the number of teeth on the ring gear by the number of teeth on the pinion gear. I think that would be better as ring and pinion tooth counts vary from axle to axle, for example a 3.54 ratio in a CJ Dana44 would be a 46/13 but a 3.54 ratio in a CJ Model 20 is a 39/11.
 
#8 ·
OhioYJ said:
I would just explain how the ratios are determined, by dividing the number of teeth on the ring gear by the number of teeth on the pinion gear. I think that would be better as ring and pinion tooth counts vary from axle to axle, for example a 3.54 ratio in a CJ Dana44 would be a 46/13 but a 3.54 ratio in a CJ Model 20 is a 39/11.
good point. Those numbers are out of my factory manual for the '88, so D35 specific. Great thread btw, definitly adding that!
 
#10 ·
#11 ·
D0ntTr3ad0nM3 said:
Ares:
Dont know if this will help you, but heres a link on the 8.8 I've gotten through doing my research. It seems that it might be of interest to you.

http://www.jeepsunlimited.com/forums/showthread.php?t=674123

GREAT write up otherwise, really helpful. :thumbsup:
Wow, that thread has a ton of 8.8 stuff. Nice find. Added info for the 8.8 from there and added that link. Thanks alot, the thread is starting to come together pretty well. :cheers2:
 
#14 ·
Talk about a workout to read.

I Vote for a STICKY!!!!!!!!!!!!!!!
 
#17 ·
Nice info! :)

You may want to correct the 8.8 brake info if you're talking about the Explorer style 8.8's which most folks use as a swap donor into a Jeep. The drum brake equipped 8.8's were from '91-'94, discs from '95-'01.

Good thread. I helped Tim (T.Dome) put together the loooooong JeepsUnlimited 8.8 thread over on the TJ Forum.
 
#18 ·
awesome awesome awesome thanks
 
#20 ·
Just a note: The AMC20 is only a 2 piece axle on the CJ, the J-trucks and Wags are 1 piece axles and are stronger. You can thank the CJ version for giving them a bad rep. I've been told the only thing needed on the Wag version is to weld the tubes to the housing. I have a 20 in the rear of my YJ, no issues yet.
 
#21 ·
Thanks learfxr for that fix. its been added.

I just did the "big" update. I added more identification information about diff cover identification with the jpg Chris sent me. I also was able to get some help on model years outside the jeep family for the D60, D70 and D44 from OhioYJs information. I fixed the info given to me by learfxr and Joe, and I added a section in each axle for stock gearing. I knew some, but not as much as I wanted so I was undecided about putting it in. If you see any that are empty or missing that you know the gears that came in it let me know and I will add them
 
#22 ·
Rockwell - indistructable.....

not true. I have seen pics of a guy break a rockwell shaft. Bouncing his way up the grand staircase in Disney, OK. it can happen, it just doesnt happen often.
 
#23 ·
Tulsachokehold said:
Rockwell - indistructable.....

not true. I have seen pics of a guy break a rockwell shaft. Bouncing his way up the grand staircase in Disney, OK. it can happen, it just doesnt happen often.
Haha, yea...I just added that in. I was watchin some custom truck show the other day and they were putting in gigantic rockwell 2.5 ton axles...IN PLACE of their D60/D70
 
#25 ·
I didn't see this in you r write-up so I thought I would help in the info.
The chrysler 8.25 that comes on the XJ's are 27 splines (91-96) and then they change to 29 splines (96-01). The KJ still uses the 29 spline version of the 8.25...though it is coils in the rear.

Nice write up:thumbsup:
Kevin
 
#26 ·
Hey, check out the last post in the FAQ. Thanx Sentinal :thumbsup: