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Old 11-23-2011, 12:23 AM   #1
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strengthening the stock d44??

looking for a little bit of info on exactly what the title says

d44 stock with lsd

whats the easiest and most effective, for the money and time involved, to strengthen up that axle

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Old 11-23-2011, 02:09 AM   #2
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Aftermarket stronger axle shafts would be a good place to start. Can do on your own. What size tire is your goal? Superior gears to match tire size, some kind of full case locker to fit your terrain. Lots of possibilities.

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Old 11-23-2011, 02:25 AM   #3
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superior offers 33 spline shafts,add a truss

what kinda wheeling are you doing and your reason for beefing it up?
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Old 11-23-2011, 10:45 AM   #4
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There are two ways to strengthen a D44, stiffen the housing itself or by replacing the carbon steel axle shafts with alloy shafts that are available in 30, 33, or 35 spline. Most are fine with a simple upgrade to an alloy 30 spline shaft like the Evolution Series from Superior Axle which gives a dramatic increase in axle shaft strength. Few need to go to the 33 spline which requires a new carrier and far fewer require a 35 spline shaft.

Superior Axle also makes a truss for the Dana 44 (Dana 35c too) that significantly decreases axle housing flex. I installed one in my previous TJ, here's a pic of that truss.
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Old 11-23-2011, 02:58 PM   #5
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Installing a stronger alloy 30 spline shaft is literally just sliding out the old shaft and sliding in the new.....no other adjustments needed?
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Old 11-23-2011, 03:17 PM   #6
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Quote:
Originally Posted by jarradfiorito View Post
Installing a stronger alloy 30 spline shaft is literally just sliding out the old shaft and sliding in the new.....no other adjustments needed?
That is correct, it's a pretty simple job. All you have to do is slide the new seal, bearing, and bearing see down onto the new axle shaft and then press the bearing and bearing retainer in place with a press. Any machine or 4x4 shop should have a press who can do it for you for $10-20. Then slide the old shafts out and slide the new shafts in and reinstall the bracket that holds it all into the axle housing. Pretty simple.

Stu's website in the drivetrain/axle section at http://www.stu-offroad.com/index.shtml has a good writeup on how to do it. His site is down at the moment but should be back up later.

Below are a few pics from when I did the same thing. The second pic shows it before the bearing retainer on top is pressed down to hold the bearing in place. The part on the bottom is the axle retainer bracket, don't forget it!
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Old 11-23-2011, 03:35 PM   #7
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You can order axle shafts with the bearings and retainers pressed on as well. Then all you need to do it is slide em in.

Northridge4x4 Jeep Parts: Rear Axles
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Old 11-23-2011, 05:08 PM   #8
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How much is a 30 spline shaft. If I run 35s with a D44 do u recommend?
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Old 11-23-2011, 05:26 PM   #9
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If you have a rear locker with your 35" tires and push your Jeep hard on tough trails, alloy 30 spline axle shafts are a good idea. The ad above your post shows Alloy USA selling imported axle shaft kits for $330 but I'd go for Superior Axle's US made Evolution series (a bit more exensive) which includes a lifetime warranty.

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