YJ Waggy Axles and Springs Build - JeepForum.com
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post #1 of 40 Old 12-21-2009, 06:36 AM Thread Starter
jaxtell
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YJ Waggy Axles and Springs Build

I think I have located and am getting a set of last generation Wagoneer Dana 44 axles, springs, steering and a set of wheels. I am trading for them, hopefully this weekend. This will be a slow build, since times are tight.

My jeep: YJ with 2.5 and 5 speed, completely stock, 30 x 9.5 Buckshot Mudders on factory rims.





My plan: Rebuild the axles, 4.10 - 4.56 gears, Posi in the back, locker in the front. Wagoneer springs (SUA) and steering. Lock-outs on the front.

My purpose: Street jeep with trail riding capabilities (not the ultimate rock crawler). Must drive decently while being able to perform well off-road.

My questions:
• I've seen lots of posts on Waggy Springs, but none SUA with Axles swapped at the same time. I know they will extend the wheel base, will it be enough to leave the driveshafts alone?
• Do all late model Dana 44s use thick cut gears that will work on the Wagoneers higher gear (lower numerically) carrier?
• I've also read use the Waggy pitman arm, will this be long enough if the front axle is relocated forward using the Waggy springs?
• I've also seen many combinations of re-packing the Waggy springs, if you are using the SUA, what combination are you running?

Thanks,
jerry


Last edited by jaxtell; 12-21-2009 at 09:00 AM. Reason: Pictures
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post #2 of 40 Old 12-21-2009, 11:10 AM
kmj153
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Project SOA 2nd. thoughts - Pirate4x4.Com Bulletin Board

1990 YJ, Waggy 44's, 4.56, ARB's, 35's, 4.2 w/ Howell FI, Stak Dana 300 RAC, w/ JB 4:1 and 32 spline output, undercoverfab belly up
2005 F-150, DD/Tow rig
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post #3 of 40 Old 12-21-2009, 11:54 AM
bgredjeep
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What size tires are you planning to run? For 33-35" tires I'd go ahead and gear to at least 4.88 to help out the 4cyl. You could go lower depending on how fast you think you need to go on the highway.

I was able to use the stock waggy steering when I swapped axles (had to ream the pitman arm), and it still worked ok when I installed the 4" waggy springs. Keep in mind that if you use the stock waggy steering and the YJ pitman arm you will not have as good a turning radius as original. The arm on the waggy knuckles are longer than the YJ. I installed a Parts Mike highsteer arm to correct this on mine.
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post #4 of 40 Old 12-21-2009, 12:07 PM Thread Starter
jaxtell
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bgredjeep: Right now, I'd say 33's, maybe some skinny 34's. I'm hoping to lacate some slighlty used Rodeo gears (I think I've read they'll work in the front and the back Dana 44s). I'm more of the "drive like you borrowed it, it will last longer" school of driving.

Forgot, kmj153: Thanks for the link, I looked at that one and saw the first picture and thought it was a SOA build, I should've read further...

Last edited by jaxtell; 12-21-2009 at 12:38 PM.
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post #5 of 40 Old 12-21-2009, 05:34 PM
YJames90
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Off topic:
What the hell is that pink thing in your first picture? Im afraid!!!

Quote:
Originally Posted by Poke View Post
Spring Over is not for you.... yet





My 2.5 to 4.3 swap thread

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post #6 of 40 Old 12-21-2009, 07:20 PM Thread Starter
jaxtell
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Quote:
Originally Posted by jamesx2 View Post
Off topic:
What the hell is that pink thing in your first picture? Im afraid!!!
A friend of mine Craig (Blue Samurai) Built his daughter a 4 peron buggy. Owner fabbed Dual Toyota Transmissions, owner fabbed Billet Aluminum Control Arms, he did all the tube work. King Air Shocks, Toyota Axles. First trip out, she's 14.

http://ctoff-road.com
jerry


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post #7 of 40 Old 12-22-2009, 05:40 AM
YJames90
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looks industructable

Quote:
Originally Posted by Poke View Post
Spring Over is not for you.... yet





My 2.5 to 4.3 swap thread

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post #8 of 40 Old 12-22-2009, 07:33 AM Thread Starter
jaxtell
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It was the first time out for this rig, did really well, but it was our first time at Durham Town, it was more of a mud bog than anything, so we didn't get to ride many trails.


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post #9 of 40 Old 12-22-2009, 12:21 PM Thread Starter
jaxtell
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New Question related to the original post:
• Are all low pinion Dana 44 carriers the same? (Can I rob a carrier that has 4.88 gears and put it into the waggy housing, I know the thick cut gears have to go on the high gear carrier).


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post #10 of 40 Old 12-22-2009, 04:24 PM
bgredjeep
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Yep. d44 is a d44 pretty much. I think the Rubicon is the only one that was different. All the others (as long as its a low pinion, 30 spline) should work fine.
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post #11 of 40 Old 12-30-2009, 07:20 PM Thread Starter
jaxtell
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Picked up my axles yesterday!
Front and rear Dana 44s from a Last Gen Wagoneer, all steering linkage and sway bar, 4 waggy wheels, a front driveshaft, and coming soon 4 front Wagoneer leaf springs. It's a start! Here they are:




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post #12 of 40 Old 12-31-2009, 12:29 PM Thread Starter
jaxtell
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Quote:
Originally Posted by jaxtell View Post
New Question related to the original post:
• Are all low pinion Dana 44 carriers the same? (Can I rob a carrier that has 4.88 gears and put it into the waggy housing, I know the thick cut gears have to go on the high gear carrier).
So I found a set of gears VC (very cheap) and the ad reads, "These came from a late model 2004 Jeep Rubicon and have been confirmed to work in standard rotation Dana 44 axles with the 3.73 down carrier."

Will the gears from the Rubi 44, bolt-up to the high gear carrier (lower numerically) in the Waggy Axles?


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post #13 of 40 Old 01-02-2010, 08:38 AM Thread Starter
jaxtell
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Anyone,
2004 Rubicon Dana 44 gears on a Factory Wagoneer Carrier?


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post #14 of 40 Old 01-02-2010, 11:17 AM
Douglas S.
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Subscribed, I'm interested to see what you do for the drivers side spring perch on the front axle. I still haven't figured out how I'm going to work that out.

1991 Land Cruiser HDJ81

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post #15 of 40 Old 01-02-2010, 01:32 PM
wrangler76
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I just built a HP D44 from a '75 F-150 axle housing cut down to the 80's waggy width. I used a spare set of BTF dana 30 spring perchs that I had lying around the shop. They sit a bit higher than stock but kept me from having to do much grinding at all on the center housing. I don't know how to post pictures on here but I'll email them to ya. And all the dana carriers should be be the same for all the housings

Also, the rubicon D44 high gear carrier should be identical to your Waggy high gear carrier so the gears should be interchangable. How much did you get the gears for?
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