cdawall

There have been quite a few axle swap threads in the past forever. Its about time for some sort of FAQ that covers some of the information pertaining to what can easily and usefully swapped into an XJ. This thread will constantly update as new information becomes available. Main reason for this "guide" is I am deployed right now and need to keep my mind off the wife and kiddo.

Stock XJ's in themselves come with several different axles.

Front Axles

• Dana 30 High Pinion (reverse cut): Used 1984-1999
  • 1984-1991: Vacuum Disconnect (1989-1995 with ABS carry 5-297x ujoints others carry 5-260x ujoints)
  • 1992+: Non-disconnect (all 1996+ 5-297x ujoints)
• Dana 30 Low Pinon (standard cut): Used 2000-2001
  • All axles are non-disconnect and carry 5-297x ujoints

The rumored strongest of these axles is a 1984-1991 with a CAD delete and the 5-297x ujoint shafts. This is due to its fully cast housing. The 5-297x axles are normally capable of handling 35s locked on the stock shafts with a driver that does not beat on it. This is still considered risky and it is recommend you upgrade to 27 or 30 spline chromo shafts. Open on 35s is plenty doable on stock shafts. The 5-260x ujoint is a weak little bugger open or locked it is not recommended going over a 33" tire on trails.

Strength Guide

1. Dana 30HP 5-297x
2. Dana 30LP 5-297x
3. Dana 30HP 5-260x (CAD)
4. Dana 30HP 5-260x (non-CAD)

Rear Axles

• Dana 35: 1984-2001
  • 1984-1989: non c-clip, 27 spline, 1.18" diameter shafts, 7.58" ring gear, 2.62" axle tube
  • 1990+: c-clip, 27 spline, 1.18" diameter shafts, 7.58" ring gear, 2.62" axle tube
• Dana 44: 1987-1989
  • 30 spline, 1.31" diameter shafts, 8.5" ring gear, 2.75" axle tube
• Chrysler 8.25": 1991-2001
  • 1991-1996: 27 spline, 1.17" diameter shafts, 8.25" ring gear, 3" axle tube
  • 1996+: 29 spline, 1.21" diameter shafts, 8.25" ring gear, 3" axle tube

Oh these axle's the strongest is the Dana 44 owing to its non c-clip design larger ring gear and large 30 spline shafts. The Dana 35 non c-clip is marginally better than the c-clip version, but still has a weak housing, thin tubes etc. The 8.25" sits right smack dab in the middle. A D35 is only good to about a 33" tire open or locked over that the housing and weak shafts are a major let down, the Chrysler 8.25 27 spline is very similar to this, but do to a better housing 35's open would be comfortable. Locking a 29 spline on 35's would be fine with most drivers. The Dana 44 on the other hand has no problems running locked 37's great axles if you can get your hands on them. All of these axle's are direct swaps that means take out axle ... and replace it with ...

Strength guide

1. Dana 44
2. Chrysler 8.25 29 spline
3. Chrysler 8.25 27 spline
4. Dana 35 non c-clip
5. Dana 35 c-clip

~~

Now that you can figure out what axle you have and how they stand in the real world you can upgrade.

cdawall

Common axle upgrades for the XJ while keeping standard width and not cutting down a fullwidth.

Front axles

• Ford Dana 44 58" WMS to WMS
  • 1971-1975 Bronco: drum brakes, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-260x ujoints, 2.75" diameter tubes
  • 1976-1977 Bronco: disk brakes, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-260x ujoint, 2.75" diameter tubes
• Jeep Dana 44
  • 2003-? TJ Wrangler Rubicon:
  • 2007+ JK Wrangler Rubicon:
  • 1980-1982 Wagoneer: Non-disconnect
  • 1983-1985 Wagoneer: Vacuum disconeect

Now getting into the swaps is a huge argument. The stock early bronco D44 is a great swap if you replace the outers with with ones that support the larger 5-297x ujoint. This still leaves that same weak point that is found on a D30 however overall the entire axle is substantially stronger. The TJ D44 is an 8.5" thirdmember with D30 tubes, shafts, hubs, outers etc. It is not a useful D30 upgrade. The JK D44 with bracing can be strong enough for 37" tires about the same as a standard D44. It is not a bad axle, but parts are hard to come by for it and there is only one locker at this time for it and it is the stock one. Any D44 gears will fit it if you bore out the mount holes.

Rear Axles

• Ford 8.8 31 spline
  • Explorer 1990-2001 59.5" WMS to WMS
    • 1990-1994: Drum brakes, c-clip, 31 spline, 1.32" diameter shafts, 8.8" ring gear, 3.25" axle tube
    • 1994-2001: Disk brakes, c-clip, 31 spline, 1.32" diameter shafts, 8.8" ring gear, 3.25" axle tube
  • Ranger 58" WMS to WMS
    • 2002 FX4: Drum brakes, c-clip, 31 spline, 1.32" diameter shafts, 8.8" ring gear, 3.25" axle tube, 4.10 gears, Zexel Torsen gear driven LSD
    • 2003+ FX4 Level II: Drum brakes, c-clip, 31 spline, 1.32" diameter shafts, 8.8" ring gear, 3.25" axle tube, 4.10 gears, Zexel Torsen gear driven LSD
• Ford 8.8 28 spline
  • Ranger
    • 1986-1992: Drum brakes, c-clip, 28 spline, 1.29" diameter shafts, 8.8" ring gear, 2.75" axle tube, ~56" WMS to WMS
    • 1993-2008: Drum brakes, c-clip, 28 spline, 1.29" diameter shafts, 8.8" ring gear, 2.75" axle tube, 58" WMS to WMS
    • 2009+: Disk brakes, c-clip, 28 spline, 1.29" diameter shafts, 8.8" ring gear, 2.75" axle tube, 58" WMS to WMS
  • Aerostar 4.0L 2WD
    • 1990-1997: Drum brakes, c-clip, 28 spline, 1.29" diameter shafts, 8.8" ring gear, 2.75" axle tube, 3 link, TrakLok limited slip
• Ford 9" (listing the ones that are correct width)
  • 1967-1973 Mustang/Cougar: Light duty, thinnest housing, small bearings, 28 and 31 spline.
  • 1957-1968 1/2 ton trucks and passenger cars: Medium duty, big bearings, 28 and 31 spline
  • 1967-1973 Ranchero/Torinos/Fairlanes: Strongest housing, 3.25" tubes 31 spline
  • 1969-1977 Galaxies/Pickups: Strongest housing, 3.25" tubes 31 spline
  • 1971-1977 "Early Bronco": Strongest housing, 3.25" tubes 31 spline
• Wagoneer D44
  • semi float, 30 spline shafts, 8.5" ring gear
• Dodge D60
  • Full body: semi float, 35 spline shafts, 1.50 diameter shafts, 9.25" ring gear, 3.12x.25" diameter tubes.

cdawall

Now for the big boys, fullwidth axles. I am going to break these down the best I can. Also sticking to drivers side drops.

Front Axles

• Ford
  • Dana 44
    • 1966-1970 F100/F150: Drum brakes, Kingpins, High Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-260x ujoints, 2.75x.5" diameter tubes
    • 1971-1972 F100/F150: Drum brakes, Balljoints, High Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-260x ujoints, 2.75x.5" diameter tubes
    • 1973-1975 F100/F150: Drum brakes, Balljoints, High Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-297x ujoints, 2.75x.5" diameter tubes
    • 1976-1977 F100/F150: Disk brakes, Balljoints, High Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-297x ujoints, 2.75x.5" diameter tubes
    • 1978-1979 F100/F150: Disk brakes, Balljoints, High Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-297x ujoints, 2.75x3/8" diameter tubes
    • 1961-1965 F250: Drum brakes, Kingpins, Low Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-260x ujoints, 3.00x.5" diameter tubes
    • 1966-1968 F250: Drum brakes, Kingpins, Low Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, ? ujoints, 3.00x.5" diameter tubes
    • 1969-1975 F250: Drum brakes, Kingpins, Low Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-74x or 5-309x ujoints, 3.00x.5" diameter tubes
    • 1976-1977.5 F250: Disk brakes, Balljoints, Low Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-297x ujoints, 3.00x.5" diameter tubes
    • 1978-1979 F250: Disk brakes, Balljoints, High Pinion, 30 spline, 1.31" diameter shafts, 8.5" ring gear, 5-297x ujoints, 3.00x.5" diameter tubes
  • Dana 50
    • 1998-2002 F250: Disk brakes, Balljoints, High Pinion, 30 spline, 1.31" diameter splines, 1.21" diameter shafts 9" ring gear, 5-806x ujoints
  • Dana 60
    • 1978-1979 F250 High GVWR/F350: Disk brakes, Kingpins, High Pinion, 35 spline, 1.50" diameter shafts, 9.25" ring gear, 5-332x ujoints, 3.125x.5" diameter tubes
    • 1985-1991.5 F350: Disk brakes, Kingpins, High Pinion, 35 spline, 1.50" diameter shafts, 9.25" ring gear, 5-332x ujoints, 3.125x.5" diameter tubes
    • 1992-1999: Disk brakes, Balljoints, High Pinion, 35 spline, 1.50" diameter shafts, 9.25" ring gear, 5-332x ujoints, 3.125x.5" diameter tubes
    • 1999-2004: Disk brakes, Balljoints, High Pinion, 35 spline 1.50" diameter inner shafts, 30 spline 1.31" outer shafts, 9.25" ring gear, 5-332x ujoints, unit bearing
    • 2005+: Disk brakes, Balljoints, High Pinion, 35 spline 1.5" inner/outers, 9.25" ring gear, 5-332x ujoints, unit bearing, same inner/outer C's as the "super" 60
  • Dana "super" 60
    • 2005-2010 F350 (V10 4.30 gear ratio): Disk brakes, Balljoints, High Pinion, 35 spline, 10" ring gear, 5-1550x ujoints, 3.75x.5" diameter tubes
    • 2005-2010 F450/F550 (medium Duty): Disk brakes, Balljoints, High Pinion, 35 spline, 10" ring gear, 5-1550x ujoints, 3.75x.5" diameter tubes
    • 2011+ F450 (class 4)/F550: Disk brakes, Balljoints, High Pinion, 35 spline, 10" ring gear, 5-1550x ujoints, 3.75x.5" diameter tubes
• Dodge
  • Dana 44
  • Dana 60
    • 1994-1999 2500/3500: Disk brakes, Balljoints, Low Pinion, 30 spline, 9.25" ring gear, CAD
    • 2000-2001.5 2500/3500: 2500/3500: Disk brakes, Balljoints, Low Pinion, 32 spline, 9.25" ring gear, 5-332x ujoints, 3.125x.5" diameter tubes, CAD, unit bearings
    • 2001.5-2002 2500/3500: 2500/3500: Disk brakes, Balljoints, Low Pinion, 32 spline, 9.25" ring gear, 5-332x ujoints, 3.125x.5" diameter tubes, CAD, unit bearings
  • Dana 70
    • 1958-197? W300: Kingpins, Low Pinion, 23 or 35 spline, 10.5" ring gear, 1.5" diameter splines
  • AAM 9.25"
    • 2003+ 2500/3500: Disk brakes, Balljoints, High Pinion, 35 spline, 9.25" ring gear
• Jeep
  • Dana 44

Rear Axles

• Chevy
  • Dana 60
    • 1964-1977 3/4-ton Trucks: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
    • 1975-1987 1-ton Trucks and Suburbans: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
    • 1979-1991 1-ton vans: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
    • 2001-2010 1-ton vans: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
  • Corporate 10 bolt
  • Corporate 12 bolt
    • 1973-1981 K5 Blazer: semi float, c-clip, 30 spline, 8.875" ring gear,
  • Corporate 14 bolt
    • 1973-1996 3/4 and 1 tons: full float, 30 spline, 1.50" diameter splines, 1.34" diameter shafts 10.5" ring gear, 3.25x.5" tubes, removable pinion support
  • AAM 14 bolt
    • 2007+ 2500/3500: Disk brakes, full float, 1541 alloy 30 spline, 1.50" diameter splines, 1.34" diameter shafts 11.5" ring gear, 3.375x.5" tubes, No support bearing, paper gasket
• Ford
  • Dana 60
    • 1955-1985 3/4 Ton Trucks: Full Float, 30 spline, 9.75" ring gear, 1.31" diameter shafts
    • 1955-1976 1 Ton Trucks: Full Float, 30 spline, 9.75" ring gear, 1.31" diameter shafts
  • D60u
    • E250/E350: Full Float/Semi Float*, 30 spline, 9.75" ring gear, 30 spline: 1.31" diameter shafts, 32 spline: 1.375" shafts
      • *note E250's utilize semi float axles, E350's full float, Certain 32 spline E350 rears utilize the same hubs as the D70u allowing the usage of 35 spline shafts without boring the hubs out. Late models switch to 8 on 170mm, 1999-200? is 8 on 6.5" with disk brakes.
  • D70
  • Dana 70u
    • 1980+ E350: Full Float, 32 or 35 spline, 10.5" ring gear, 32 spline: 1.375" shafts, 35 spline: 1.5" shafts
  • Dana 80
    • 1998-2003 F350 DRW: Full float, 35 or 37 spline shafts, 11.5" ring gear, 35 spline: 1.5" shafts, 37 spline: 1.625", 4.375" OD axle tubes
  • 9"
  • Sterling 9.75"
    • 1999+ 1/2 trucks/SUV/Vans: semi float, c-clip, 1050 steel 34 spline, 1.37" diameter shafts, 9.75" ring gear, 3.25x.180" diameter tubes
  • Sterling 10.25"
    • 1985-1992 F250/F350: Drum brakes, full float, 35 spline shafts, 1.50" diameter shafts, 10.5" ring gear
    • 1992-1999 F250/F350: Drum brakes, full float, 35 spline shafts, 1.50" diameter shafts, 10.5" ring gear, better shaft protrusion to carrier
  • Sterling 10.5"
    • 1999-2009 F250/F350: Disk brakes, full float,35 spline, 1.50" diameter shafts, 10.5" ring gear, 3.375x.5" tubes
    • 2009+ F250/F350: Some have been confirmed to run 37 spline shafts rest of the axle remains the same
• Dodge
  • Dana 60
    • 1966-1970 Coronet & R/T: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
    • 1966-1972 Charger & R/T: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
    • 1968-1972 Super Bee: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
    • 1970-1971 Challenger: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
    • 1963-1993 2500/3500: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
    • 1994-2002 2500 (V8 Only): Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
    • 2004-2006 SRT-10: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
  • Dana 70
  • Dana 70u
  • Dana 80
  • AAM 14 Bolt
    • 2002+ V8 2500/3500: Disk brakes, full float, 1541 alloy 30 spline, 1.50" diameter splines, 1.34" diameter shafts 10.5" ring gear, 3.375x.5" tubes, No support bearing, re-usable rubber gasket
    • Ram Power Wagon: 2500/3500: Disk brakes, full float, 1541 alloy 30 spline, 1.50" diameter splines, 1.34" diameter shafts 11.5" ring gear, 3.375x.5" tubes, No support bearing, re-usable rubber gasket, E-Locker
    • 2002+ 2500/3500: Disk brakes, full float, 1541 alloy 30 spline, 1.50" diameter splines, 1.34" diameter shafts 11.5" ring gear, 3.375x.5" tubes, No support bearing, re-usable rubber gasket
• Chrysler
  • 8.25"
  • 9.75"
• Jeep
  • Dana 60
    • 1968-1973 Jeep J3800/J4800 Camper Truck: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts
    • 1968-1970 Jeep J-2600/J2700/J3600/J3700: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
    • 1971-1973 Jeep J4600/J4700: Semi Float, 35 spline, 9.75" ring gear, 1.50" diameter shafts
    • 1974-1988 Jeep J20: Full Float, 30 spline, 9.75" ring gear, 1.46" diameter shafts

cdawall

Added a couple more axles in. Working on the list a lot of info to read through...

cruiser54

Great job. Thanks.

Kamaran

Umm if we are aloud to post cool if not a mod can delete this for me?

The front D30's didn't all get 297x's..ony the ABS and the 96+ got the larger joints.

cdawall

Thats listed in there and people can post away it is still a normal thread If you mean on the low pinions I am specifically speaking about the XJ D30LP available in 00-01 which is all 5-297x
If you see anything else LMK so I can update and try to keep this as accurate as possible.

Thanks

Kamaran

95 swapped to 96 for 297X but your dead on with everything else..and yup I missed or skipped right over the the ABS part clearly lol. Didn't even see it posted haha

Great list so far though bud

cdawall

need to find more rear axle info it seems harder to find than front axle info.

johnydoe

great thread, good job....this stuff should be stickied at the top beside the "lift & tires"

cdawall

can't edit my posts anymore :/

Gorillaxj

Just more wagoneer/grand wagoneer info...
they came in a NT(narrow track) and WT (wide track) option. the narrow track is about 61.5" in the front (about 1" wider the stock) the rear narrow track is 58.5" which is about 1 inch narrower then stock to allow better turning radios for the full sized vehicle. this will also help turning radios when swapped into the xj.

82-84 had a vacuum disconnect option.
80+ is drivers drop front diff (same as xj)
79 and older is passenger drop and will not work without a lot of fab.
80-91 is D44, open knuckle, disc brakes, big bearing and the knuckles out are all chevy parts which makes everything cheap and easy to find. Also makes hysteer and cross over steering very easy with chevy flat top knuckles, as they just bolt on and are cheap compared to aftermarket setups.

85 and older the rear axles where mostly AMC20 one piece (the good model) and where equaly as strong as the D44 rears, but get a bad rap from the two piece weak style that cam in the CJ's.

86 and newer came with the D44 rear axle. Some had an offset rear diff and is not as ideal for the swap as the centered rear diff. but both are usable. the off center diff came with the quadratic 4x4 system.

the axle front tubes are 3" and rear axle tubes are 2 3/4"

some axle internal info.
8.5-Inch Ring Gear Diameter
1.31-Inch / 30-Spline Axle Shafts
1.38-Inch / 26-Spline Pinion
3.73 & Down / 3.92 & Up Carrier Break
Standard Cut Gears
Low pinion design
297x U-Joints
Leaf Spring Setup
Disk Brakes
6x5.5 Wheel bolt pattern

Wheel Mount Surface to Wheel Mount Surface was 61.5 Inches on mine (some report 62.5" threw 60.5") I think the discrepancy is in how its measured. but its not a big enough difference anyways.

Good site for WMS-WMS measurements (not all axles but a good amount)
http://members.***.net/tadsal/WMS.html

Hope it helps some.

clayton3854

can a mod please give cdawall the ability too continueally edit this post and make it an official sticky posted with sticky for all size n brand lifts made? this brings up a thought.. maybe make a sticky like this for say sye as well and maybe different brands of tires etc? just stickys for items that always get millions of threads started where main question is why this one opposed too that one and will this work with this? just an idea too clean up the forum from having so many diff threads basically asking same thing. since the lift one was added iv used that and posted it on so many threads its a huge help as i know this one will be too.

Browny10783

nice, thanks

Gorillaxj

Just use this to add/edit info and create a new locked thread with the info once it all added together. then make it a sticky so we can link people to it who don't search lol