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Old 04-04-2013, 07:35 PM   #1
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Dana 60 to my TJ, will it work ?

Hello Everyone

I am new to the forum, and I would like to ask you for some advice.
I am from Poland and I couldn't find anyone on my local forum who could help me with this one.

What I would like to do is to get rid of me old Rear DANA 35 Axle Assembly, Because I have no lockers on it and with my 35 inch wheels it keeps breaking all the time :/ .

I have a SUPER DANA 30 with ARB Air locker in the front and I would like to keep it cause it works like a charm and I never had any problems with it.

... Now I was thinking about buying a DANA 44 with ARB Air locker or maybe going one step ahead and go for the DANA 60 with the same locker, let say this one.
G2 Axle and Gear Part TJRJR488ARB - TJ Rock Jock Dana 60 Rear Axle Assembly 4.88 Ratio With ARB

Will I have any difficulties to fit it with my DANA 30 ? My jeep is a 1997 TJ.
Or just upgrade to DANA 44 ? like this oneG2 Axle and Gear Part D44TJ-A48835 - TJ D44 Rear Axle Assembly 4.88 ratio; With ARB Locker and 35 Spline Axles

Thank you for all your help in advance.

Adrian

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Old 04-04-2013, 07:48 PM   #2
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Szalik, I can tell you from my G2 RockJock60 install that the axle is quite large. To install it axle in my jeep, I had to do a tummy tuck and have my driveshaft shortened a couple inches. The pinion on the 60 is quite long. I really should have stretched my wheelbase when I did the install. I am not able to comment on the G2 Dana 44 except that it would be a much simpler installation. It has all of the brackets in the factory locations and should bolt directly in. The dana 44 pinion is a bit longer than the dana35, so you may still need to have your driveshaft shortened a bit. Good luck!

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Old 04-05-2013, 03:54 AM   #3
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Thanks for the reply.

How about the weight of DANA 60 is it much heavier than DANA 44.
And another question, is DANA 60 really indestructible. My Dana 35 breaks quite a lot and I was thinking about installing ARB Air locker on it. But will it make it stronger ? Than I thought maybe DANA 44, buy then again I have to shorten the shaft and few other modifications.

I wanted to buy DANA 60, because I believe that I should last for at least few years of harcore offroad.
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Old 04-05-2013, 05:33 AM   #4
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For 35s a d60 should be more then enough. The d35 is a time bomb ecpessially if you put a locker in it. However there is the issue of size with the d60. I believe the d60 pumkin is too big to fit without a aftermarket gas tank or relocated gas tank. D44 should hold up fine to 35s.
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Old 04-05-2013, 07:45 AM   #5
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So what do you think D44 will be enough ? and what would be the best Locking system for it. I have a ARB Air locker in the front, should I install another for the rear let say with the Dana 44 ? Locker should strengthen the Dana 44 as well.
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Old 04-05-2013, 08:00 AM   #6
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Why not build an 8.8? You should be able to build cheaper than buying a D44 and far cheaper than a D60 with a lot less modifications. An 8.8 is stronger than a D44 and will easily handle 35s. I'm currently building one for my TJ.


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Old 04-05-2013, 08:02 AM   #7
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a 60 will be far stronger than the d35. I ran front and rear 60's on my TJ years ago with 35" tall tires... had to get new driveshafts etc.. You can get a rear dana 44 with 33 spline shafts which is more than fine forth 35-37" tires and will have more ground clearance than most standard dana 60's...
below is pic's of my front 60..to give you an idea on size at least in a front axle.. no good pic's of the rear. its also a prorock 60 so a bit smaller than most 60's
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Old 04-05-2013, 10:26 AM   #8
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Thanks ALL Terrain TJ The problem is that 8.8 is very hard to get in Poland- especially if something breaks. To be honest I think that it will be the same with DANA 60 and there are too many modifications, the clearance also will be worse.

The problem is, that in front I have DANA 30 and if D60 is wider It will be very hard to synchronize everything.

4Jeepn Thanks for the images. It looks very impressive, nice car.
I hope that D44 with ARB Air locker will survive my driving
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Old 04-05-2013, 10:52 AM   #9
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Welcome to the forum. Try to keep us updated (I'm thinking you're going with the D44's) and let us know how everything turns out. Good luck...
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Old 04-05-2013, 01:56 PM   #10
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Quote:
Originally Posted by Szalik View Post
Thanks ALL Terrain TJ The problem is that 8.8 is very hard to get in Poland- especially if something breaks. To be honest I think that it will be the same with DANA 60 and there are too many modifications, the clearance also will be worse.

The problem is, that in front I have DANA 30 and if D60 is wider It will be very hard to synchronize everything.

4Jeepn Thanks for the images. It looks very impressive, nice car.
I hope that D44 with ARB Air locker will survive my driving
Trying to fit a D60 is nowhere near the same level as fitting a D44 or 8.8. And and a traditional 60 has worse clearance than an 8.8.

I don't think you've thought through even half the things you need to run a D60.
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Old 04-05-2013, 04:15 PM   #11
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Thank you for all the advises and suggestions. I think I will chose the D44 with ARB Locker. Will keep you updated. Now I have just bought new parts for my D35 cause it was on the warranty, but I believe it wont last too long. Next one will be 44. Tomorrow I am going for Offroad rally, I just wish to come back on 4 wheels , that the rear wheel drive will survive.
I will try to post some photos if I will have any.

Thanks again
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Old 04-09-2013, 06:28 AM   #12
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Last question. Which axles should I choose with D44 33 or 35 spline ? Any difference in strength ?
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Old 04-09-2013, 06:00 PM   #13
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35 spline is stronger than a 33 spline
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Old 04-10-2013, 06:45 AM   #14
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why not get the axles out of a Early bronco, dana 44 front and Ford 9" rear, you'd save your self a LOT of money and have plenty of axle for a 35" tire however it would not be a simple bolt in process, you'd need to make mounts to fit your TJ or custom make mounts. I run a d44/9" on my TJ with 35s. I also run 1ton disc brakes front and rear, don't forget to upgrade your brakes. you need to stop with those big tires.
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Old 05-24-2013, 05:20 PM   #15
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Hello

I thought that I will give you an update about what is going on with my jeep and at the same time ask for little help.

Since my last post my Dana 30 and Dana 35 broke 3 times. I had enough ! :/ and after a lot of search on the internet I have made a decision about what to do with this car.
Because the market of used parts in Poland isn't very big, actually I didn't have much choice and after many phone calls I have found a housing(Front and Rear) from a Nissan Patrol GR Y60. They are quite strong and should last for a long time.

Other modifications are: Finally Instead of weak 2.5l Engine I will put 4l one and automatic gear box from Jeep cherokee + Dana 300 Transfer Case.

And the last one is a problem. I have searched everywhere for Dana 300 and there is nothing available in Poland. I have found some in US, on ebay but nobody is willing to ship them to Poland, even for a higher price.

My request is: Do you know anybody who has and will send a Dana 300 Transfer Case to Poland/Europe ? Otherwise I will never finish this car. I have tried to call people in US and spend many $ for just the phone calls and still nothing. Please help !

Thx

Adrian

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