Originally Posted by WineCountryWheeler
Hi guys, 2012 JKU Sport here. I am building a TERA44 right now to put in the front. I currently have the rear locked with an ARB RD117 30 spline locker. I have purchased the ARB RD147 35 spline locker for the new front axle.
Should I run the 35 splines up front, or swap the lockers and run the 35 spline in the rear and 30 spline up front? Any reasoning as to why?
I will be buying new chromo shafts for BOTH axles soon and so that's also why I am asking.
So I offer this as a possible solution. I did the same thing a year ago. Built a Tera 44 housing 35 spline RCVs, ARB, High steer knuckles, Dynatrack ball joints for my JK.
But as you, I had an ARB in the rear with 30 spline Chromoly axles and wanted to upgrade. I sold the axles for $350 and used the money to purchase the following ARB PN: ARB728H031. It is the internal parts needed to convert your 30 spline ARB to 35 spline. I still spent another $600 for a set of G2 Gold Placer axle shafts but now I was 35 spline front and rear.
People will say that this moves the weak point to the gear set and there is some truth to this but I have built 75 or more sets of Jeep axles for people that both daily drive and beat the crap out of them off road. I have yet to see a broken set of JK (this is important) Dana 44 gears.
The JK Dana 44s are not the same as the old Dana 44s. They actually almost named it a Dana 48 because of all the changes they made but held onto the 44 for some reason. Bigger and thicker ring gears, larger pinion shafts and larger bearings, many changes made to the housing to increase rigidity. It is a much stronger and improved axle over the old Dana 44s. Failures are not that common. Not saying they never happen just not common. I wouldn't shy away from 35 spline axles worrying about your ring and pinion unless you are captain "When in doubt POWER OUT" of obstacles.
I also built a rear housing with all Artec HD brackets and positioned everything for my 4 inch lift with the correct pinion angle, Spring perch position and track bar location at the same time. It's funny but it also improved the suspension articulation a bit. I think turning the stock housing causes a little bind in the control arms maybe near full flex?
Good luck with your project.