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The $25 Dana 30 Build Thread....

IslanderOffRoad

NAXJA Forum User
NAXJA Member
Location
Houston, Tx
On Sunday, I was browsing CL for Jeep parts when I found an ad, no pictures that said "Jeep Cherokee 4x4 Axles, $25." No pictures, no further description. I thought it would probably be just shafts, but figured it was worth a few minutes of my time to investigate. Turns out the guy was selling front and rear axles for $25 TOGETHER. Just wanted em gone. I asked him about the origin, and he said a 95 Cherokee 4x4 Automatic. Told him I'd be over shortly.

When I got there, I was shown some axles sitting under a tarp in his backyard. I feared the worst, but the front looked pretty good- it was a HP, Non Disco 30. The rear... I have no idea. It definitely wasn't from an XJ, it had Coil and Control Arm Mounts... Maybe a ZJ. He said they may have been from a Grand, it was his brother's Jeep the axles came out of. But the front was right, so I told him I'd give him $25 for just the front and he could still sell the rear (would have taken it but I don't have the space).

Of course at this point my imagination started to run wild since it was an XJ front and a ZJ Rear. Maybe it had been swapped in at some point, and had a 3.73 ratio or something!

Today I picked up a drain pain so I could open up the $25 D30. Apparently the whole axle has been painted blue at some point... just covered in grime.

The Axle:

122CCF69-36B9-4CEF-B07A-5F3FA06BD36D-20973-000012A5EC69D58D.jpg


Redneck Tie Rod strengthening:

31148C50-F016-41BA-AF3B-A5F3D5D3BDEB-20973-000012A5F57622CF.jpg


And the gears. Ended up being 3.55, but they're in good shape. No slop, no missing teeth, nothing. I've got 3.07's in the rear, and was planning to just go 4.10's, but the cheapass in me is saying to just find a matching rear now.

EA385DD6-DD1B-4649-83CC-B6530538C503-20973-000012A5FB1565DD.jpg


Gonna start cleaning it up on Thursday when I'm off and have some daylight.

I've done some D30 building before on my last XJ, here's what I have planned for this one:

Regear(maybe at this point)probably 4.10's
Selectable Locker
LCA Skids
Brace Pass Side UCA
Gusset inner C's
760 shafts
Use the knuckles/unit bearings/etc from my 98
New Ball joints and bushings

I've thought about trussing it but honestly overkill for my needs. What am I overlooking that I should be adding to that list at this point?
 
I'm building a hp30, I just brace the inner front area of the ps upper mount with and the inner upper C's with 1/4 plate,plated the face of the trackbar mount to prevent it from wallowing out, used some 3/8's plate for the skids on lca mounts and tied them into the axle tube. It was scrap my father had laying around so it didn't cost me a thing.
 
either keep the 3.55s or re gear to 4.88, dont bother with 4.10. I had 2 Xjs on 35s for a while, both built, both on 35s. one had 4.10s , manual, one still has 4.88s, auto. I wish the manual had 4.88s.
 
either keep the 3.55s or re gear to 4.88, dont bother with 4.10. I had 2 Xjs on 35s for a while, both built, both on 35s. one had 4.10s , manual, one still has 4.88s, auto. I wish the manual had 4.88s.

35s are not part of my plan. And Texas is much flatter than Cali so the deep gearing isn't as necessary.
 
Good call
 
I believe I have a D30 4.10 R&P somewhere. Possibly carrier and Master install kit.
 
Update on this. Been busy at work, been sick, weather's been awful, but I finally got a chance to clean the thing up!

Here's a pic of it after some serious wire brush time and a couple coats of Rustoleum Hammered Black. The knuckles didnt get painted since I'm gonna use my existing ones just to make sure the unit bearings and everything all work together right.

FF70C98C-04DC-4125-9A54-D741E37A9E34-6312-000006398EBF3FE6_zps2fa7b551.jpg


I'm kinda concerned about the UCA bracket though. Ya'll think I can bend this back in shape or should I get someone to burn a new one on? When I was wire brushing it, the UCA busing popped right out.

F38D8A56-2750-40D6-BCBA-1C85931FE9EA-6312-000006398867DCC4_zpsea9b8324.jpg
 
How hard would that welding work be for a noob with a cheapo welder? I get my bonus later this month...
 
How hard would that welding work be for a noob with a cheapo welder? I get my bonus later this month...

I just boxed mine a couple days ago, and it wasn't that tough. I am a beginner welder and it turned out decent considering my limited welding skills and I was using a little 110v welder. The way I looked at it was that it's just a D30, if I screwed it up, they are cheap and plentiful. Just take your time and go for it. It cost me $1 for a 8"x8" piece of 1/8" plate from my local welding shop's scrap bin.
 
It cost me $1 for a 8"x8" piece of 1/8" plate from my local welding shop's scrap bin.

cut it with the torch as well? or am I looking at more tools...
 
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