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Ok, so I'm going to build a Dana 44 rear, and eventually the front too, but not right away. Any help on gears, lockers and axles would be much appreciated.
I currently have the stock Dana35/30's, 3:07's, 4.0 IL, 5sp HD Manual, Command-Trac P/T 4WD.
 

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what tire size do you plan to run as lots of answers/info will be based off that.
 

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I like the 33x12.5x15's, for now but might go to 35's, but no taller, and right now I do very mild off-roading, but I want to go on more aggressive trails.
 

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Tj 44 in stock form will be fine for upto 35's.. Might need to change gears at some point, but over all no issues.. If you put a locker up front in the dana 30 you might want to think about running alloy shafts... for gear wise your looking at 4.56 which will work with 33's and 35's.. you could go to 4.88's but that might be a bit too low for everyday driving with just 33's.
 

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Thanks, 4Jeepn, Was wondering if 4:56 in D30 would be wise even with alloys and locked. May be just unlocked for now, till I cn find a D44 front
 

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Thanks, 4Jeepn, Was wondering if 4:56 in D30 would be wise even with alloys and locked. May be just unlocked for now, till I cn find a D44 front
You will be fine up to 35s on the Dana 30. I wheeled the hell out of my last tj with 35s. I would recommend better shafts and even a truss which I had. If u know ur gonna go to 35s go with 488s though with the 5 speed
 

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Thanks, Jcole231. I am not clear on the "truss," which you said would improve the reliability of the D30. What is it and how is it applied?
 

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It does make the D30 look beefier Jcole231, but how much of a diff costwise between this or just buying the D44 front with stronger hardware.
 

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It does make the D30 look beefier Jcole231, but how much of a diff costwise between this or just buying the D44 front with stronger hardware.
There's not a whole lot of difference between the two other than the actual diff. From the differential out is the same on both, axle housing diameter, outer Cs ect. Truss and C cussets will only run u around 175ish. But to give u an example I just bought a used front D44 for 1800 that had the stock rubi locker and the ring and pinion I needed. Not a great price but fair. If u are 100% sure ur gonna stay in the 33-35" tire range, I honestly would keep the D30 and build it up a little. You will hear lots of different opinions but from personal experience the D30 is stronger than people give it credit for.
 

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Jcole231, not to be nosey, but you said you just picked up a D44 front, and I was wondering if this is going on your Jeep, and if so do you want to sell your front?
 

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It does make the D30 look beefier Jcole231, but how much of a diff costwise between this or just buying the D44 front with stronger hardware.
D44 center pumpkin is more liable to bend and break then the D30. Just because of how it's shaped and where the shear points end up. If you need a truss on the 30, then you should really put one on the 44 front. I'd wait on dumping a lot of time and money polishing a turd if you plan on beefing it up later. I'd just get some chromos and gears. That way if you step up you can sell it or the parts, and not take a massive loss in the end on labor/personal time.
 
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