building the bullet proof D30 housing

[IntrepidXJ]

The fact of the matter is the 44 is already sitting in my garage (from a 79 f250) but I want to see how far I can take a dana 30 - and after all, it was my money to waste.

that's funny....i have an HP D44 from a 78 f-250 in my garage and am continuing to build up my d30. i'm saving the 44 for when i finally decide i want to go with bigger tires

 

[cal]

I have another four wheel drive thats - gasp - more important to me than the cherokee, that I think's getting the hp44.

1962 Ford F100 4x4 Shortbed Unibody small rear window. The fifth year of the first overhead valve engine ford ever made (223ci i6), 4th year of factory 4 wheel drive. I broke a knuckle on the lp closed knuckle 44 a couple years ago, and while I found a replacement, its eats a kingpin bearing every 8 thousand miles or so and leaks grease into the front right brake drum. About two years ago I blew up the ford 9" in the rear and threw a 60 back there, so now it's time to do a front to match. Originally I grabbed the hydro assist stuff I listed above to go on that setup, but I think the jeeps going to get it instead.

Here's the old rear end. First housing failure I ever dealt with. I'm hoping not to have housing problems on the d30

 

[Jump This]

that's funny....i have an HP D44 from a 78 f-250 in my garage and am continuing to build up my d30. i'm saving the 44 for when i finally decide i want to go with bigger tires

Ummm...could you load that 44 onto the plane with you when you come on out...I'll supply cash incentive!!
Rick R

 

[IntrepidXJ]

Ummm...could you load that 44 onto the plane with you when you come on out...I'll supply cash incentive!!

i will use it one of these days....so no thanks. though, it would be funny to see what the airline says if i dragged in an axle to be checked

 

[hadfield4wd]

i will use it one of these days....so no thanks. though, it would be funny to see what the airline says if i dragged in an axle to be checked

You could put it in a golf club bag.

 

[Mr.OverKill]

truss is fit up and the vent mod is designed, i just need to fit the vent tube in and seal it up prior to welding the truss on, the truss is 2X4 square tubing and tight as i could get it to the dif and tubes, i will try to get pics tomorrow. hoto:

 

[GSequoia]

Try, make sure to fab up a few practical jokes for Cal to find after he gets it. I don't think they make him work enough at work so he needs something to occupy his mind.

 

[cal]

dude f* off. I havent had a day off in several weeks and it's making you less funny

 

[Mr.OverKill]

dude f* off. I havent had a day off in several weeks and it's making you less funny

( to the tune from lion king ) can you feel the love tonight........

 

[Mr.OverKill]

here is the truss pics i promised

other than these gaps at the dif ( needed for the vent tube and alignment issues ) the largest gap is 1/16" along the tubes to reduce the risks of warpage

well i have alot of welding to do in the very near future, every thing is tacked or just sitting on the axle untill cal gives it the once over and the go. the UCA mounts are the seccond to last things going on along with the shock mounts. then once we mount the axle on the jeep we will design and fit up the track bar mount.

questions comments or concerns are welcome

TIA

 

[cal]

It looks good! I need to hurry up and order material for the trackbar and some other goodies (DLE's, a few more superflex joints, etc). I'll try and nail down tonight what my weekend schedule looks like, so I can roll down your way. I'm thinking sunday, but thats my 30th birthday and everyone seems to think its more important I see them than you?

I'll give you a call in a couple hours or in the morning, depending how work goes.

-C

 

[dallas xjs]

awsome work...with evo axle shafts i would put that up against any {well almost any} d 44...what about hydro assest on those knuckles??or a factory weld knuckle at that?? hats off to you and crew on that 30 build..||charles||

 

[Jump This]

awsome work...with evo axle shafts i would put that up against any {well almost any} d 44...what about hydro assest on those knuckles??or a factory weld knuckle at that?? hats off to you and crew on that 30 build..||charles||

Ohhhh GAWD!! Don't give these hackers any ego boost yet!

I still havn't seen Cal in his Jeep in over two years!
(and we are still kinda' ticked at Cal for spending two weeks on the Con without inviting all of us!)
Rick R

 

[ashmanjeepxj]

here is the truss pics i promised

other than these gaps at the dif ( needed for the vent tube and alignment issues ) the largest gap is 1/16" along the tubes to reduce the risks of warpage

well i have alot of welding to do in the very near future, every thing is tacked or just sitting on the axle untill cal gives it the once over and the go. the UCA mounts are the seccond to last things going on along with the shock mounts. then once we mount the axle on the jeep we will design and fit up the track bar mount.

questions comments or concerns are welcome

TIA

The trusss looks nice but dosent do much for the short side. coil buck kills the strength.

I havent finished burning mine in yet.. Its 2x6 3/8inwall box on a d60

 

[Mr.OverKill]

The trusss looks nice but dosent do much for the short side. coil buck kills the strength.

the truss is more to provide a weld point for the UCA mount on the dif and long side strength. the truss really isnt needed because the doubled thickness of the tubes ( 3"X1/4" wall tube over the 2.5"X1/4" wall stock tubes ) besides the paramiters of the coil bucket were spacific, the coil could not sit any more than 1/2" over ( higher than ) the stock bucket location.

 

[cal]

I'm confident the housing will never be the weak link in this axle. Troy is doing work far beyond my expectations. I just hope i'm able to return the favor to him.

 

[Jump This]

I'm confident the housing will never be the weak link in this axle. Troy is doing work far beyond my expectations. I just hope i'm able to return the favor to him.

Troys just hoping to be able to pick the damn thing up when hes done!

Rick R

 

[Mr.OverKill]

Troys just hoping to be able to pick the damn thing up when hes done!

Rick R

they dont say that i have a 7500lb tubular XJ buggy for nothing!!

 

[flexinxj]

im loving the idea! ive been wanting to build my D30 and D35 and so many people are against it - NO FAITH! its all about living and learning, if it breaks you can always find a way to make it stronger (it just might cost alot)
whats with everybody wanting 1ton axles? theres no fun in that - fun is knowing you (and maybe some buddies) built it yourself to handle what your gonna do to it!
keep us posted even after you get it done - I WANNA KNOW WHAT HAPPENS

 

[GSequoia]

Actually Flexin I wouldn't bother building up a 35. XJ 44's are common enough and easy. The 30 is a bit different as it isn't too terrible an axle and can hold up decently - not that it isn't still a gamble