I want to do a Dana 44 swap from a 1990 Wagoneer (SJ) to my 1990 XJ. I was wondering if anyone has done one before? Belwo is a link to the axle that I think I want to use.

http://www.lowmileageparts.com/1990-...x#.W5cFkPYnaM9

 

With enough fab work you can do the swap but it isn't a direct bolt in. I believe it is also a low pinion axle. What size tires do you plan on running?

 

I am running 32x10.5x15 currently and don't plan on going any bigger. I would like to go with manual lock out hubs and 4.56 or 4.10 gears.

 

It's one of the most overrated swaps ever.

Yes, I've done it. No, I would never do it again.

For 32s I would keep the D30 any day. There is (or was?) a manual hub conversion kit out there, but it's not really something that is needed most of the time.

 

A high pinion Dana 30 will be fine with 32" tires. You can get locking hub conversion kits for them but it isn't worth the price in my opinion.

 

you sure that's an SJ axle? it' looks like a high pinion, and a waggy is an xj platform. the SJ was a grand wagoneer.

 

Yeah that doesn't look like a SJ axle at all.

The pinion yoke is different, the brake rotors are different. And it have coil springs. SJ axles were leaf spring.

 

The SJ was the Wagoneer from 1963-1983. When the XJ was introduced, they renamed the SJ to the Grand Wagoneer and gave the Wagoneer name to a trim package on the XJ. So only 1984-1991 SJs were called Grand Wagoneer.

And looking at that picture, that axle looks nothing like an SJ Dana 44. The SJ 44 is low pinion with big obnoxious hubs that stick way out, even when they're set up with drive slugs instead of locking hubs.

I put a set of axles from a 1988 SJ under my XJ. Mostly just because I could and I wanted a project. Sure the front is stronger than a D30. But the rear 44 isn't really any stronger than an 8.25. Though it is an upgrade over a D35.

Several things to know about the swap:

1. They are 6 on 5.5" bolt pattern, which is nothing like an XJ. If you do the front, you'll want a matching rear.
2. The front is low pinion. Even with a moderate lift, I'm needing a double ended double cardan driveshaft to keep it from vibrating on the highway.
3. No matter how you do it, you're going to need to do some significant fabrication. Even with the truss kit that comes with all the brackets, the TNT customs kit requires substantial work.
4. Steering is easy. You can use a drop pitman arm from an SJ on your XJ steering box. From there, factory SJ steering components bolt up.
5. The front axle drives the coast side of the gears, which is not the most desirable setup.
6. No matter what axles you go with, you're probably going to need to modify your driveshaft.

There are better options for swapping in a Dana 44 into the front of your XJ. And, quite honestly, the factory D30 will handle 32's just fine. And lockout hubs are overrated.

 

Thank you for the tips and knowledge I will most likely stay away from the swap and passably do a high pinion 30 instead. As I do not plan to go bigger than 32 I want something I can drive on the highway and moderate trails. Has anyone used a spin free locking hub kit that isn't $1500? This is something I would like to do but not at that price point.

 

Why do you need locking hubs? You already have the vacuum disconnect high pinion Dana 30 front axle in your 90. The vacuum disconnect operates a collar that couples and uncouples the passenger side axle shaft from the differential. Serves the same function as locking hubs. Jeep realized in later years the fuel efficiency difference with the front axle disconnected was negligible and did away with the disconnect.

I have 33s on my jeep. I daily drove the jeep for a year with no problems. Fuel mileage is decent for the size of tires. I regeared both axles to 4.10 and the jeep drives great.

I'm sorry to say I think you are trying to fix a problem that isn't a problem.

 

Ask yourself this.

Would you trust "cheap" hubs to hold up?

 

They don't make free spin kits that are cheaper than the Dynatrac or Yukon kits.

 

right. but he posted 1990 wagoneer

he could still use that axle posted tho, it will bolt right up to his xj as long as he matches gear ratios.

not all 1990 xj's have vac disco. only the 231 equipped does. the limiteds with 242 have abs and non disco axles, which is what i swapped in my 90 pioneer from my 89 limited.

 

Good Catch. I should have remembered that. I had an 89 with the 242 and it didn't have the vacuum disconnect. Around here 242s are not very common, I have only seen one - the one in a parts Jeep I bought looking for a 231. If I had been looking for a 242, I never would have seen one. Worked out ok though, I sold the non-disco axle for $200. The last disco axle I sold I had trouble getting rid of it, let it go for $75 - no one wanted it.

Perhaps OP actually means the XJ Wagoneer. Shouldn't be too hard to find an older XJ with the vacuum disco and swap it into his if he doesn't have the disco. Throw an ad on CL offering to trade your non-disco for a disco axle. Not too many gear choices, shouldn't be hard too find one with the same ratio.

The disco axles aren't the strongest option, but if you are sticking with 32s and only do moderate wheeling, you should be fine.

 

The kit is expensive because it requires a lot of parts to make it work. There's just no good way to do it with anything that's off the shelf/mass produced.