I'm pretty sure I have a bent axle on my '99.
Taking it to a gear shop today to confirm but to plan for the worst case scenario, I need someone to point me to some new dana 30 prices. I've seen the G2 axles at 4 Wheel Parts- anyone know of anywhere else to get a good HP Dana 30 27-spline geared at 4.56?

Would it be more economical to get the casing from a junkyard and pay to have the gear swap done, or do I risk getting another bent casing?

 

I doubt another JY one would be bent if you did that.

I think JY would be cheaper + gear set up

 

Yeah, as long as I stay away from ones totaled because of front end collisions, right? Even better if I find one full stock because it probably hasn't been wheeled much.

What else do I need- a master rebuild kit and new gear set? I think after I pull a JY axle, buy the gearset, bearings, labor for installation, I'd be getting close to over a thousand. If I want to get it reinforced I think I'm looking at closer to $1500, so that's why I'm wondering whether I should simply opt for a new, trussed and assembled axle.

 

How realistic is it to think mine could be straightened if it is in fact bent?

 

I don't think that would be easy to do, d30's run about 100-200 bucks locally at least in western mass where i'm from. I think your best option would be to pick up a new d30, (high pinion preferably) and build that. You could even consider putting a 4.10 d30 in there and finding a 4.10 rear axle to match.

 

I already have a 8.8 geared to 4.56 in the rear. Is the straightness of the axle something I can check with a straightedge? Where's the best place to find a basic D30 with perches etc. already in place?

 

Your in Colorado?

I'm sure craigslist will have something for you...

 

You can't bend the axle tube back, the only fix would be to have it retubed. Is your bent d30 already geared to 4.56? If the ring and pinion looks good still you can reuse it.

 

X2 if the ring and pinion look ok i would re use them, that'll save a little bit.

 

I've had some luck finding craigslist axles but I'm not sure how confident I can be that they're straight. Last time I had the cover off the ring and pinon looked great.

Is it just a matter of holding a straight edge to the axle tube to check whether its straight? I suppose I could check the caster of the spring perches too...

 

Alright, after taking it to a trusted axle & gear shop, they seem to think its mainly tire noise and even if it was something going out, there's no real way to tell without taking the axle apart. During the test drive the owner of the shop admitted it sounded rough though.

 

Not too many bent axles find their way to CL.

I got a pair, D30 and 8.25, for $100 cash. I just confirmed it was a d30, and that was it.