5:24 pm
Club Member
January 20, 2009
Offline
I may have an opportunity to replace one of my complete axles in the near future. I plan to stick with 35" tires, eventually getting the larger 35" MTR Kevlars, and move to 4.88 gears.
I currently have the following:
1992 Jeep YJ 4.0L Manual
Front: HPD30, TJ Replacement Shafts (non-chromo and YJ disconnect block off), ARB, 4.10 Gears
Rear: D35, 30-Spline Chromo Shafts, ARB, 4.10 Gears (also have spare shafts)
First thought is to do the front and get the more expensive option done and out of the way, but the rear is a D35. It's held up okay so far with the chromo shafts.
Option A: Replace HPD30, get new axle with 5x5.5 and 4.88 gears, re-gear the rear to match, get wheel adapters for the rear, and new wheels.
Option B: Replace HPD30, get new axle with 5x5.5 and 4.10 gears, get wheel adapters for the rear, and new wheels. Re-gear the front when I replace the rear.
Option C: Replace D35, get new axle with 5x5.5 and 4.88 gears, re-gear the front to match, get wheel adapters for the front, and new wheels.
Option D: Replace D35, get new axle with dual bolt pattern and 4.88 gears, re-gear the front to match. Get new wheels when I replace the front.
Option E: Replace D35, get new axle with dual bolt pattern and 4.10 gears. Re-gear the rear and get new wheels when I replace the front.
Option ?
I left out which axle I'll be replacing with as it has not yet been decided but will be something heavy duty.
Is D60 overkill for 35s? Solid Axle makes a really heavy duty D44.
I could also go 6x5.5. The wheel adapters are an inch thicker.
Thoughts? 
8:57 pm
January 12, 2007
Offline My opinion:
Do not put a D44 in the rear. I have wheeled with you and you need a 60 back there.
I dumped a couple grand into a rear 44 and it lasted 2 seasons. I broke an axle which ended up wiping out the ARB too. š„ Also bent the housing. That money could have gone into my 60 in the first place and saved some money and time.
10:46 pm
Club Member
July 10, 2003
Offline 60 in the rear...end of subject.
I used to wheel a lot. . .
1:28 am
Club Member
January 20, 2009
Offline 60 in rear is fine. I'm thinking G2 RockJock in rear and maybe Solid Axle HPD44 or G2 RockJock in front.
What I'm wondering more about is, which one should I do first, front or rear? Either way I have several options (see above).
If there is an option I have thought about please let me know. (Can't do both right now. š )
2:33 am
Club Member
July 10, 2003
Offline "kevheb" wrote:
What I'm wondering more about is, which one should I do first, front or rear?
60 in the rear...end of subject.
60 in the rear...end of subject.
60 in the rear...end of subject.
60 in the rear...end of subject.
...is there an echo in here...
I used to wheel a lot. . .
2:53 am
Club Member
January 20, 2009
Offline "JohnDF" wrote: [quote="kevheb"]
What I'm wondering more about is, which one should I do first, front or rear?
60 in the rear...end of subject.
60 in the rear...end of subject.
60 in the rear...end of subject.
60 in the rear...end of subject.
...is there an echo in here...
Okay, I take it you mean the rear. 
Would you go with Option C, D, or E?
6:19 am
Club President
April 2, 2003
Offline Option c...
2:34 pm
Club Member
July 10, 2003
Offline "BKGM Jeepers" wrote: Option c...
Agreed
I used to wheel a lot. . .
3:28 pm
July 15, 2005
Offline Which one first? Replace the axle housing that you have broken the most while wheeling. You have broken your front and not your rear. That 35 will last a lot longer wheeling that your 30 up front will. Don't waste your money on name brand axles like Currie, Tera, etc. With your leaf spung Jeep, you can do junk yard axles for cheap. My opinion is that if you reallly never plan on going past 35's then I would do a 60 in the front and a Toyota axle in the rear. You could probably do both for less than $2500..Shop Craigs list and Pirate for deals. The Dana 60 will hang down a lot, but the nice part is they are strong and you can bash them over rocks. The Toyota has good clearance and can handle a 35 inch tire with no problem what so ever ( Just ask Keane). With the front 60 you will need to get it narrowed, so have them shave the pumpkin at the same time you have it narrowed. You also really need to look into an anti-rap bar for your rear axle. You have been really lucky to date that you haven't rapped those rear springs the way you like to hammer the gas pedal over rocks
__________________
'If we ever forget that we're one nation under God, then we will be a nation gone under."- Ronald Reagan
4:00 pm
Club Member
July 10, 2003
Offline "RobD" wrote: if you reallly never plan on going past 35's then I would do a 60 in the front :
If he really never plans to go over 35" tires, then I say put a good Dana 44 in front. It will be more than strong enough and have much better clearance.
With a 60 in the rear (and 35s), he can slide over rocks with a little throttle. With a 60 in the front (and 35s), he will be banging into stuff and getting hung up all day long.
I used to wheel a lot. . .
6:07 pm
Club President
April 2, 2003
Offline Yet another counterpoint.
I ran a LPd30 in a TJ on 37's with an ARB and the only thing I broke was a poorly maintained u-joint.
I also ran a HPd30 on a TJ with 37's and an ARB. This axle was built pretty well. It never had any problems.
If you are looking for ground clearnance, only plan to run 4.88 gears and never higher, and 35's, modifying your existing HP30 is a relatively inexpensive option.
a 60 up front (especially a wrecking yard unit) will hang very low. Check prices as they are getting more and more expensive (Just ask Scott).
The 60 in the rear is a good direction becuase you can evaluate where to spend your money next with something that works and won't need to be replaced in the future.
7:24 pm
July 15, 2005
Offline I still say go 60's front and rear. I remember when I was saying that I will never go past a 33 inch tire, then I swore I would never go past a 35, then I swore I would never go past a 37, now Iām on 40's and will be going to 42's next time I buy tires...Point here is never say never. Wish I would have done it right the first time, Instead I had three different front axles and 3 different rear axles...Either keep what you have and build them or do it right so you never look back and say, I wish I would have listened. As little as you wheel now Kevin, it would be cheaper to keep and build what you have and just carry spare parts. Spending money to build custom axles for a 35 inch tire is kind of a waste of money in my opinion...Alloy axles and a set of CTM's would work just fine
__________________
'If we ever forget that we're one nation under God, then we will be a nation gone under."- Ronald Reagan
7:49 pm
"JohnDF" wrote: [quote="RobD"]if you reallly never plan on going past 35's then I would do a 60 in the front :
If he really never plans to go over 35" tires, then I say put a good Dana 44 in front. It will be more than strong enough and have much better clearance.
With a 60 in the rear (and 35s), he can slide over rocks with a little throttle. With a 60 in the front (and 35s), he will be banging into stuff and getting hung up all day long.
Wow, I like this thread. Its got some really good ideas and got me thinking. My choice for Kevin could actually be used for myself. A Rob/John hybrid of Toyota rear axle and aftermarket 44 like John has. I would never of thought of using a Toyota rear over a Dana 60 on a Jeep, but its actually not a bad idea. It's lighter, plenty strong and better ground clearance than a 60. The big assumption is the 35 tires being the maximum you would ever run, but the Toyota rear would be cheap to find and not much of a loss if you later changed to a D60. I would look for a used Toyota rear with 4.88 gears and a D44 like Johns.
3:15 am
Club President
April 2, 2003
Offline "RobD" wrote: I still say go 60's front and rear. I remember when I was saying that I will never go past a 33 inch tire, then I swore I would never go past a 35, then I swore I would never go past a 37, now Iām on 40's and will be going to 42's next time I buy tires...Point here is never say never. Wish I would have done it right the first time, Instead I had three different front axles and 3 different rear axles...Either keep what you have and build them or do it right so you never look back and say, I wish I would have listened. As little as you wheel now Kevin, it would be cheaper to keep and build what you have and just carry spare parts. Spending money to build custom axles for a 35 inch tire is kind of a waste of money in my opinion...Alloy axles and a set of CTM's would work just fine
I recall you broke something on your rear 60 with 40's. What was it? I'm moving up to 38's and wanted to know the weak links in my HP 60...
4:23 am
I'm with Rob on not buying some name brand. At least get a price from someone local to build you one. I've never compared them cost wise, but I'd imagine you can save a few bucks and I'm not really willing to pay for a name. Saves you shipping and you can wait for the right deal on a housing or pull one at a junk yard. Fronts are probably tough, but I've found rears. You can also probably do a lot of the work yourself. Pay someone to cut it down and weld on perches and go from there.
I'd go 60 and just be done. Who was that guy on the first hammers run with 60s on 35s? He drove the thing like he stole it, but it held up without any problems.
I'm not sure I'd go Toyota, but I don't have a reason. Plenty strong and plenty reliable.
I don't like any of your options. š They all seem to end up throwing money at an axle that you're going to get rid of. Why not buy that Ford in the 4sale section? Use the 60. Trade the 10.25 for a 60 and part out the rest. Live with the wheels on the truck. Keep it 8 lug and save some money. The neighbors and the wife will love you for it. It's overpriced but you can work from there.
If you're going to have to pick front or rear. Do the one that you break or worry about the most.
5:02 am
Club Member
January 20, 2009
Offline Thanks for all of the info! š
6:54 am
buy this and steal all the goodies , put yours on it and sell it for about the same. if i had the money i would.: http://monterey.craigslist.org.....77526.html
6:56 am
Club Member
July 10, 2003
Offline I agree with Rob that if you ever see yourself going past 37" tires then I'd go straight for a D60 front and rear. I just dissagree that it should be the front first, it'll be like dropping 2 tire sizes.
I used to wheel a lot. . .
6:58 am
Club Member
July 10, 2003
Offline "bobf777" wrote: buy this and steal all the goodies ,
It's in Soledad...all the goodies are probably already stolen
I used to wheel a lot. . .
1:24 pm
July 15, 2005
Offline I have broken the ring gear which caused the Atlas TC yoke to break in half when the ring gear broke and froze. I have also bent an axle shaft...
"BKGM Jeepers" wrote: [quote="RobD"]I still say go 60's front and rear. I remember when I was saying that I will never go past a 33 inch tire, then I swore I would never go past a 35, then I swore I would never go past a 37, now Iām on 40's and will be going to 42's next time I buy tires...Point here is never say never. Wish I would have done it right the first time, Instead I had three different front axles and 3 different rear axles...Either keep what you have and build them or do it right so you never look back and say, I wish I would have listened. As little as you wheel now Kevin, it would be cheaper to keep and build what you have and just carry spare parts. Spending money to build custom axles for a 35 inch tire is kind of a waste of money in my opinion...Alloy axles and a set of CTM's would work just fine
I recall you broke something on your rear 60 with 40's. What was it? I'm moving up to 38's and wanted to know the weak links in my HP 60...
__________________
'If we ever forget that we're one nation under God, then we will be a nation gone under."- Ronald Reagan
2:21 pm
Club President
April 2, 2003
Offline What shafts are you running Rob? Are they superiors? Did they warranty them?
My TJ runs superiors which are supposed to be lifetime. I think the G2's in my JK are only 3 years.
3:58 pm
FWIW i would take a look at complete rigs on CL. i have seen some YJ's for sale that already have 60's on them for around 5000. then you either have a new rig, or pick what you want off of it and sell the rest for scrap. just my 2 cents
8:58 pm
Club Member
September 3, 2008
Offline Nobody likes the 9 inch rear? Seems that would be a great axle for 35's and if he did ever go up, he could build it to accommodate.
Um...what?
11:42 pm
Club Member
January 20, 2009
Offline It will be a 60 in the rear. š
I should have clarified that I mentioned the 44 because I was thinking of doing the front first. 
It will be a 60 in the rear. š
It will be a 60 in the rear. š
It will be a 60 in the rear. š
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