At the very least you should look into bracing the d30 housing. Its a proven fact even people who never take their Jeeps off roading can end up with a bent housing or twist the tubes right out of the center. And I would replace the stock diff since the spider gears are weak and bittle.
Travis, I say stick with the 8.8. It is stronger than a D44. I was going to go with a D44 rear until I did some reading and searching and found that it is weaker. I have a D44 front axle and waiting to be installed is an 31 spline 8.8 with c-clip eliminators, and custom shafts to match my 6x5.5 bolt pattern on my Waggy front axle. I'm running leafs all around and love them! Flex well and it sits pretty level.
If you want to keep it simple and cheaper get a D44 from a Wagoneer and then get a rear D44 from a Rodeo, same bolt pattern and disc brakes. I'm sticking with the 8.8 but this was my plan before I changed my mind.
I don't know if you're interested but I will be selling my 28 spline 8.8 soon. Lock-Right, 5.13 gears, and a Solid diff cover. Will let it go cheap if you're interested. Gears have less than 10k miles on them. I also have the adapters for the rear axle too 5x4.5 to 6x5.5 pattern. Width is great to match the front. I'm local too.
The axle shaft strength (tested by Warn Ind.) is as follows:
F8.8= 6,500 (lb. ft.)
D44= 4,600-5,000 (lb. ft.)
D35C= 4,000-4,300 (lb. ft.)
COT: Continuous output torque rating
MOT: Maximum output torque rating
Numbers from January edition of Fourwheeler, page 60.
Dana 35 rear axle COT: 870 MOT: 3480
Dana 44 rear axle COT: 1100 MOT: 4460
Ford 8.8 28spline COT: 1250 MOT: 4600
Ford 8.8 31spline COT: 1360 MOT: 5100
Dana60 semifloat COT: 1500 MOT: 5500
05' 4x4, Auto, Locked F&R, D44 SFA & 8.8 w/disc & c-clip eliminator , Yukon Chromo's F&R, Custom Skids, Sliders, Bumpers, 35" BFGs, 5.13 gears, Riddler & Solid Diff Covers, Superchips Flashpaq, CB, Optima Red Top, Gibson Exhaust, K&N Air Filter & a lot of other little things.
Last edited by outdoorsman; 11-01-2010 at 12:50 PM.
Reason: Numbers added
there are a few members with d 30s on here. Razors edge has one and runs 35s and is always out crawling around. its all in your driving style. however i cant help but think since your running with a bit more wight it wouldnt work out. i think a waggoneer 44 would be better scince your running leaves, alot of the HP 44's have cast peices on the axles and cannot be welded well enough. then you can get adapters for the rear on your 8.8 to match the width and the bolt pattern.
Aside form the multiple weak points in the HP Dana30 the reverse roation is another problem that limits the Dana30's strength. I actually went with a LP Dana44 out built for a xj/tj from G2. But I am not running leaf springs.
here are the articles i read before choosing an axle.
i was rolling down the street, heading to UNLV, and i see this white ranger with a weird *** camper.. .hahah. im assuming you were on your way to SEMA. which had to suck cause traffic was extremely bad this morning. Im sad i can't go this year....
I may have to put the axle swap on hold. The motor clunking is getting louder. Just put some heavier weight oil in the motor to make it last a bit longer. Unfortunately I may have to just rebuild the 4 banger as I still haven't found a diesel.
Yep, I was up in Vegas for the SEMA Show. I didn't have my truck in the show this year since its pretty haggard still from Mexico. I mostly went to meet a few people who came in from out of country for some projects I'm working on, and to meet manufacturers and such. Apologies if I didn't notice anyone, as I was wiped out still from working a month strait on a customers project.
I haven't had a chance to read the whole thread but I do hope, for a trip around the world, that your carrying at least 2 spare tires and rims, if not 3.. Ideally, I think a guy would want an air compressor and a portable (possibly underhood) welder as well.. I'd take an extra battery, spindle, bearings, spool of heavy gauge wire, bailing wire, hose clamps, nuts/bolts, DUCT TAPE (lol), and anything else that I could fit in that rig.
I applaud your work and tenacity though! NOT HATING ON YA..