axle decisions

[beaker]

Hi everybody
recently my rear axle has been acting up in my XJ.  Pinion seal just went and it vibrates a bit (gee, I wonder what that could be).  I want to put a dana 44 in the front and something comparable in the rear.  My goal is min 35 " tire capacity.

I want to continue using my 16" tires for now. (they are almost new and ~32" tall)
I have a front dana 44 from a 78 ford f150 already.  My trip to get it was the end of my dana 35.  I see three choices

1. I can either narrow it down (lot of work) and use typical backspacing rims and narrow a matching ford 9" for the rear.

2. I can get high backspacing rims and leave the axles factory length (5 inches wider than original axles). ~5.5 or more inches backspacing (I have multiple sources).  Tires will be sticking out another inch or more per side.

3. I can narrow the front dana 44 and put spacers / adapters on a rear chrysler 8.25 to get the 5x5.5 bolt pattern of the front.

What do you guys think?

Choices 1 and 2 mean I'll have for sale a chrysler 8.25 axle, dana 30hp, and a set of 4.56 gears and instalation kits ready to be installed (bought them, never got to it)

 

[xjmark]

If you're going to put the time and effort into modifying housings, building suspension mounts, and spending money on parts, why not do the job once and go with one ton axles. It is more money initially, but it most likely will be the last set of axles you will have to build. Think of it as an investment.

Last year I spent a ton of money building a d44 rear, and d30 front to run 33's. This year as I planned on going with a 36" tire, axle longevity became a concern. Sure, the old axle set would hold up if wheeled easily, but sometimes it takes a little extra skinny pedal to get out of a situation, and things break. If one person is broken on the trail, that means it becomes everyone's problem.

I did a lot of research and price comparison over the last six months to decide what axles to build, and found that in my case, a HP60, and 14Bolt were that way to go. Once built, they should hold up to just about any build up that the jeep will see in the long run without spending anymore money on axle upgrades.

 

[beaker]

Dana 60's are bullet proof however they are heavy and quite expensive.  I just think they are beyond what I want to do with my truck especially they way I drive it.  The expense of a long arm kit and axle is beyond what I am willing to spend. I'm guessing nearing $2000 for the front alone (900 for axle, 900 for suspension kit, 200 odds and ends).  Then wheels and tires on top (32" tire and dana 60 = poor clearance).  Plus I 'd rather not have the weight penalty too. 

I can get custom wheels that will fit my rig and full size axles (dana 44 and ford 9") for 625 delievered.  I have a line on stock type wheels that may do it cheaper.  Custom spring pockets needed,  use the radius arms to build a simple long arm suspension.

An alternative is narrowing the axles and running easy to find wheels.  ~$500 in parts and another $100-200 for used easy to find wheels. (more work but front hubs are more out of harms way).  Original spring pockets, again use the radius arms.

Mark, trust me, I've thought about the dana 60 but I don't think it's for me.  Too much additional expense for unneeded strength.  Atleast strength I don't need due to my driving style and typical tire choice.  For your strength level, the dana 60 is most cost effective, however for my strength requirements, it's not.  I do not plan on upgrading internals above factory strength components on the dana 44 or the ford 9. 

Only those upgrades necessary to fit the axles on the vehicle.  Eventually a gear change but that's later after fitment issues are taken care of.

 

[jps4jeep]

Ever consider mildly built Waggy dana 44's they are the right wideth. the only thing is you will have to change rims. I don't know of any way to get a 4.5" back spacing.

I am currently building a set of these, and when done, according to my calculations they should hold up the 36" Irocs I plan on using.

One thing is, if you like the 16" wheels, look for a set of chevy 1500 4X4 wheels from a 95-present. they are most all 16" diameter, and can be had for cheap for the older ones.

 

[beaker]

If I narrow the axles I can use normal F150 type wheels, If I keep the axle factory width I need high backspacing wheels ~5.5 plus.  Do you know what the 1500 wheel backspacing is?