Rockcrawling, Mud Running, and Four Wheeling from Nebraska

Dana 44 vs. Dana 30

(Click on any of the pictures for a larger view)

When I decided to do a solid front axle swap on the my GMC S-15 a few years ago, I was looking to upgrade the stock IFS, which had been lifted via a Trailmaster 5" IFS kit. The Trailmaster lift is a good product in my opinion, but the stock ball joints and C. V. shafts were not up to the task of carrying around a small block V8 that was powering 35 inch tires. Although I did get good at replacing the half shafts, it was starting to get a little costly to wheel the truck. After doing some research, I found that allot of people were using the YJ Dana 30. It provided a drivers side differential ( I retained the stock transfer case ) , about the same track width, an easily adapted wheel bolt pattern, and was a good mate to the stock GM 7.5 rear. As with any upgrade though you find that your truck is stronger, so you wheel harder, and find more "weak links".

The Jeep Wagoneer Dana 44 axle was chosen as the candidate for a new upgrade. No, its not a Dana 60, but my intentions are to build a truck that will run 36" or 37" tires. The 60 is a good upgrade for someone who needs it, but my truck doesn't need the extra weight or width (if left stock width), and its very hard to find one with a drivers side differential at the local salvage yard. The Dana 44 a is good upgrade to the Dana 30. If features larger u-joints, axle shafts, and brakes than the Dana 30. It also has lock out hubs, a common 6 on 5-1/2 wheel bolt pattern, and more choices for gear ratios. Most importantly ( to me anyway), the Jeep Wagoneers are plentiful in the salvage yards around here, so finding replacement / spare parts is easy and cheap.

Note the difference in size between the Dana 44 axle (left) and the Dana 30 (right). Most Jeep YJ's came with the smaller Spicer 260 u-joint in the front axle shafts. It has an average torque rating of 2900 lbs-ft. A set of 35" tires will quickly break these, unless you are light on the throttle. Most every Dana 44 came with the larger Spicer 297 u-joint. With an average torque rating of 4400 lbs-ft, it is better suited for heavy use. It is possible to upgrade the Dana 30 with larger u-joints, by using the axles from a late YJ or TJ. I put these in the axle of my own truck, and was very happy with the increase in durability. The only drawback is that you are still left with the small axle shaft diameter.

There is a slight axle diameter increase between the Dana 30 (left) and the Dana 44 (right). The Dana 30 has a 27 spline / 1.16-inch diameter axle shaft, with an maximum torque rating of approximately 4100 lbs-ft. This "smaller" axle is best suited to 31 or 33 inch tire. The Dana 44 axle is 30 spline / 1.31-inch unit, with a maximum torque rating of approximately 6000 lbs-ft. This axle shaft is suited for 35 inch tires, and should handle the 36 or 37 inch tires I have planned for the GMC S-15. If not, there are allot of aftermarket axle shafts made that can handle upwards of 9000+ lbs-ft of torque. Combine those with a set of the "indestructible" u-joints out on the market, and you could have a Dana 44 axle that would give a stock Dana 60 a run for its money.

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