Dana 30 Upgrades

[kirksjeep]

I started my Dana 30 upgrade today while the parts are in the mail.  Now this build up is not going to be as strong as a Dana 44, but it will be much better the a stock YJ.  Here is a list of the parts I ordered:

XJ solid passenger side shaft with 297 U-joints
Alloy USA U-joints- 760 that replace the 297 size
Alloy USA outer axle seals- to keep the dirt, water and mud out the axle
Solid Diff Cover
Inner Axle seal- needed to upgrade to the XJ shaft
New Poly tie rod boots
Goferit Tie rod flip kit- moves the Tie rod up 3" out of harms way
TJ 4wd indicator switch for the NP231- eliminates all the vacuum line, and still allows the dash light to work

Guys on YJ boards say that this set up "should" be ok with 35's if I don't add a locker.  When/if I add a locker I'll need to go to some chromo shafts.  Compared to the stock 260 U-joint set up I should be about 50% stronger.  After pulling the axle shafts today I am very glad I ordered the out axle seals since the shafts were covered in mud up to where the inner seal would be.  I will also say that I am glad I decided to do this in the garage and not on the trail since the unit bearings were a little tough to get out. 

I'll try to get some pics when I get everything pulled out.  There are a lot of great write ups out there if any other YJ guys are interested.

[PaulW]

MY buddies running 35's on stock 1998 xj dana 30 with full detroit and he's been ok for years.

[calvynandhobbs]

Kirk, I'm glad you're doing all of these upgrades to your YJ so I have someone to help me if I decide to do this to my XJ. I have the same D30 with vacuum disconnect. If I decide to put money into my XJ I need the rear axle replaced, SYE installed, new rear driveshaft and then go to the front axle. Although, I think my engine will quit before I get to that point. My XJ is at a crossroads with dumping money into it or just running it into the ground with the intention of buying something else.

[BayouGold]

you looking at a wrangler rog?

[calvynandhobbs]

you looking at a wrangler rog?

Yes, I've had 3 CJ7s before I went to the XJ and I miss them. In some ways I wish I never would have sold my last CJ7, but I think it was the right thing to do at the time when Pfizer announced it was closing the Ann Arbor site. I've been looking at Rubicons more than anything else, but I'm going to keep looking and putting some money off to the side to buy something.

[BayouGold]

if i had it to do all over i would go for a amberfire pearl color rubicon. i wouldn't mind getting a yj for a trail rig as i really like what kirk has done with his, but i can't even get the one i've got where i want it!

[PaulW]

if i had it to do all over i would go for a amberfire pearl color rubicon. i wouldn't mind getting a yj for a trail rig as i really like what kirk has done with his, but i can't even get the one i've got where i want it!

just stock pile jeeps like i did, when that circuit city stock matures, OH BABY!!!

[kirksjeep]

Roger I'll let you know how the axle shaft swap works out.  I'll admit I feel like I am updating my 1992 technology with 1999 technology which is still 10 years old .  In theory it should make the 4wd system much simpler with out the need for vacuum lines.

Geoff- if you can find a YJ for a trail rig you should go for it.  It would be nice to see some more square headlights

[calvynandhobbs]

Roger I'll let you know how the axle shaft swap works out.  I'll admit I feel like I am updating my 1992 technology with 1999 technology which is still 10 years old .  In theory it should make the 4wd system much simpler with out the need for vacuum lines.

Geoff- if you can find a YJ for a trail rig you should go for it.  It would be nice to see some more square headlights

I've been talking to Roger about his YJ that he has for sale a little bit. He has probably built 7-8 Jeeps over the last 6-7 years and then turns around and sells them. Here's a link to the one he has for sale right now. I took the pic of his Taco that he has as an avatar down at the Badlands Offroad Park 3 years ago.
http://www.greatlakes4x4.com/showthread.php?t=118865

[Seabee_BUC]

Go to BTC just once and all that bling is gone! LOL...Nice looking rig though!

[kirksjeep]

That Jeep does look good.  I like the Dana 300 and Dana 44 passenger side drop.  Some day I would like to do that, but that some day is a long time in the future.

[kirksjeep]

After 6 hours of wrenching the axle build up is done.  The old U-joints gave a good fight, but I eventually won.  Everything went pretty straight forward.  The tie rod flip kit hasn't arrived yet, so that will get done some other time.  I also need to hook up the TJ 4wd indicator switch, but I need to get the right plug for the switch. 

It looks like I am only going to have a 3 days of school next week, so I should have some time to work on it.

[HOT-ROD]

awesome.

give a brother a call to help some time.

[kirksjeep]

I finished the last part of the solid axle shaft conversion today.  When I removed the vacuum assembly I no longer had a working 4wd light.  I know it's not a big deal, but I like all the bells and whistles on the dash to work.  I bought a TJ 4wd light switch from Quadratech but later found out that they need a special plug.  I picked up the plug at the junk yard and today I made a wiring harness that connects under the hood and runs to the 4wd light switch.  After I ran all the wires in plastic wire loom and zipp tied everything up I gave it a test and it worked just like it should.  No light in 2wd, light in 4wd high, no light in neutral, and light in 4wd low.