Jeeps Only: Project 1

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Project 1 - Raptor > Front Axle

Actual pictures coming soon

Someone in my local Jeep club upgraded to a front Dana 44 and had a Dana 30 from a 94 Wrangler YJ just laying around in the back yard. Now I already have a Dana 30 already in our YJ but what got me interested in buying this axle was the fact that it already had a 3.73 gear ratio, the same as the rear Ford 8.8 I bought. The ring and pinion gears look to be in excellent shape so this prevents me from having to install 3.73 gears in my current axle. Furthermore, the extra Dana 30 means I can work on it a little at a time in my garage while using my YJ as a daily driver. What sealed the deal for me was the fact that this guy only wanted $75 for it. He mostly just wanted it out of his back yard. Lastly, as a bonus, it turns out the axle came with calipers and all - the whole brake assembly.

Now I know the Dana 30 isn't a heavy duty axle but since I'll only be installing 33 inch tires on Raptor (at least for now), the Dana 30 will probably be just fine with few modifications. Here is a list of modifications I plan:

Replace the weak 5-260X axle ujoints with 5-297X ujoints. Ideally I would have found a Dana 30 out of a 1995 YJ which already has the larger axle ujoints but chances of finding one cheap that had my axle ratio were slim.
Weld (have welded) new swaybar connectors since I'll be using a new ubolt bracket that will take away the stock connectors (which are built onto the ubolt bracket on the stock setup).
Have an axle truss welded on.
Swap the yoke out to one that uses ubolts instead of the wimpy stock straps.
Paint it black again (POR15?)
Maybe - Flip the tie rod up top. This is said to increase ground clearance 3 inches on the tie rod and the kit is less than $70 (some are around $25).
Maybe install the Warn hub conversion (possibly the 5 on 5.5 conversion) for a stronger outer axle and the ability to positively disconnect (unlock/disengage) the axle. This is stronger, increases gas mileage and decreases wear. Plus you could still have shift on the fly as long as the hubs are engaged.

Price: $75

Ease of installation: Bolt on replacement

Acquired 09/2003