Though only covering Dana, Nate provides Good information on the basics :

 

I thought id be the magic one that got the stock locked dana 30 with 35s and 4.88 to survive. I was wrong for a few months I broke more dana 30 stubs and u joints than I could count.
I started packing 2 long and 2 short shafts.

Finally went to chromoly shafts and havent broke since. Knock on wood . The 29" spline 8.25 with welded spinders has not sufferd any breakage even while spinning 35s on the rocks
I did break a 27spine 8.25 shafts that day I also broke a front shaft.

 

I have a friend that wheels her 13-year-old 2 door JK (she complains that it's an old jeep!??) on 35's with the factory supplied Dana 30 in front, that's been fitted with Chromoly axel shafts. She still occasionally snaps an axel shaft, but her Jeep is much heavier than our XJ's. Beeping Jeep pushed a sleeve through the housing on each side to strengthen his D-30 on an XJ - explaining that trusses take up clearance he (and the rest of us) don't have. He also installed Chromoly axel shafts.

 

Truss takes up clearance? Raised upper link mounting points with 10" of seperation takes up space. Ive raised link axle points about 2" higher then stock to improve geometry.

Im jeeps kinda heavy I couldn't say heavier then a 13 year old something or other or not but pretty heavy for a xj.

with chromoly and driving it like its weak and fragile has helped


What im finding is 2door jk is 3700-4200 depending on model trim and stuff. This weight has the 2wd falling in it to

My jeep front axle is 2200 and my rear is 2100 and change this doesnt include the full set of tools and 10 spare front shafts

 

Evan, you should post mages of your build, or better yet, showing what it can do. Do you have a truss? Her JK carries a lot of overland gear, but it's different from mine. For example, I have an Otter cooler while she carries a refrigerator with a generator to power it. Her rig sets about one inch higher in the back when she's unloaded.

 

https://youtu.be/A-OCU8sz988

https://youtu.be/5ye-83guWJw

 

COOL - looks like that low truss aligning with the top of the of the diff allows you swing that axel is style!

 

Truss is low but upper 3 link bracket is raised abouz 2" higher than factory at full stuff arm and bracket thread between frane and block.
https://youtu.be/A-OCU8sz988

 

Thanks, an amazing build - You show what it takes to place 35's under an XJ so it will hold up on the trail. Keeping the Dana 30 helps your clearance - but it's still a 30. Truss and Chrome Axels strengthen it, but I'd bet that it's still better to keep the axels as the week link, as they are easier to swap out on the trail then snapping something else?!?

 

This thing is in constant change. Ive been following buggies around and doing well. Rear suspension is probly next up. Then something to put 538 gears in


I broke an axle shaft and knuckle in the same day..
thats why im now running wj stuff. Almost every upgrade has came when that part broke. Not sure I can do much else with the 30

 

Here, let me spend lots of money for you. Eaton Super Dana 30 locker and 30 spline chromoly shafts

 

And while I am at spending your money, 30 spline RCV axles. By now you have mortgaged everything you have

 

We'lll need 14" ori struts order now and schedule the build for 6 months from now.

Probly about 2400 to ship and return it from idaho

Build will be tunable for ride height sit in 3-5" lift range. Lower the better. Will acomadate 35-37" tires

With disposable funds depending on parts availbility mainly coilovers or ori struts.
a build like this would take a couple months and probly truthfully cost 30k + . But would be streetable and badass on the trails.

even starting with a clean solid xj if it ended up at 45-50k ounce done its still a hell of a rig even compared to newer jeeps.

All that said its still just and xj

 

Yup, makes a great sleeper. Well out to the shop and wrassle with some tires