High Horsepower Front Axle Swap Ideas

AFAIK, all the CJs had the same width frame up front. The later ones got wider in the rear only. Not sure about YJs.

The bigger the tire, the less room you have between the tire and frame for steering, the wider axle you need for full steering capability. If this is going to remain street legal, check with local tire stick-out laws before you commit to anything.

If you go to a D60 and plan on using leaf springs, the sheer size (width) of the differential will create issues with driveshaft alignment. To keep enough room next to the casting for a leaf spring, the pinion gets placed closer to the center of the jeep. Be aware of this when planning. Transmission and oil pan clearances could become an issue.

 

This. If you are thinking of narrowing the closest that can be done is Wagoneer/Scout 2 width. The short side can only be shortened so much and therein lies the issue. I narrowed one for my CJ-6 that sits on a shortened Scout Terra frame and have about 3/4” between the inner “C” on the short side and the carrier where the tube goes in. Just enough room to weld it back together.
And this is at Wagoneer/Scout 2 width. Forget about any idea of CJ width.

 

Even with some big horsepower, I would be looking at building a narrowed 44. As stated above, the early Wagoneer and Scout ll axles are good donors to start with. The Scout has heavier spindles, but in a light CJ, shouldn't be a consideration. Just drive it with respect for the power! I've seen lots of mud bog race trucks running 44s successfully. Tire size, traction, and a heavy foot are what break things. Most front axles breaks I've been around have been in reverse when the front end is heavily loaded, like pulling out another stuck vehicle.
-Donny

 

Now thats a good idea if your time is valuable to you! Is anyone making aftermarket high-alloy axle shafts yet?
-Donny

 

Yes. RCVs are available too.

It’s all basically within a fraction of inch of a NT30. Keep in mind the Roxor has YJ width springs.

 

I narrowed a Scout 44 for my CJ6 to regular narrow track width and run internal spline hubs on Chevy spindles and Ford Rotors. I have a 60 in the back but you can only imagine how much I drag that boat anchor around out back. I would really recommend the 44 for clearance.

 

1100?! That's really reasonable.

 

If it is important to you, I would check on the interchangeability of parts between domestic and Roxor parts. I have heard their transfer cases are based on D 18's but, the parts are not 100% interchangeable. Much like the aluminum center section D 44's used in Grand Cherokees are not 100% interchangeable with other domestic D 44's.

 

FYI 5.38 Roxor axles are incoming.

 

hmm.....now i need a roxor to go with my roxor axle....project creep....

 

Yeah, I'm not buying one, but 1100 seems really reasonable for a front 44, but only if the parts interchange.

 

I am looking for information on this Roxor Dana 44, I can't seem to find it searching. Especially where to purchase it.

 

Purchase parts from a dealer close to you. Go to the Roxor tab on the home page, there are several threads on the parts. Everyone is just discovering the parts, not a lot of information out there yet.

 

Dang, I think you'd be at least WAY ahead with the cost of time these days to just blow the 1100. Does anyone know if these Roxor units have the same or equivalent axle shaft diameter and joints strength as a traditional 44F? What about bolt pattern? Is it still 5 on 5.5?

I've had the pleasure of swapping Waggy-width D30F, 44F SUA, 44F SOA, and truck width D44F, 10 bolt, and D60F on to the front of various CJs. The most common breaks I saw was steering knuckle joints (297x on most of these 44s I think) due to tires turned full lock stuck in some gnarly rock garden and the driver (sometimes observed from behind the steering wheel ) dumping the clutch too hard...oh, and with a locker installed.

 

Since I hear they can use 19 spline D44 spiders, I imagine "Yes" to your first question.

I know for certainty it uses 5x5.5 just like a CJ.

 

People are already making 30 spline axles for the Roxor, so you can swap in a modern 30 spline 3.92&up diff for an Air-locker or whatever:

https://www.justdifferentials.com/Mahindra-Roxor-HD-Chromoly-Front-Axle-Kit-p/axn24125.htm

By the time you buy the Roxor housing, new axle shafts, gears, hubs, and diff of choice, it will be well over $2K, but still not a bad deal all said and done. Especially since it comes with disk brakes already installed.

 

Fireball, I think you’re right about it not being a bad deal. From all the junk yard axle rebuilding and installing from other projects, Ive never been dramatically below the 2k mark when my time was factored in. Maybe 1200 or so on the least expensive front end build but that included quite a few hours of degreasing, power washing, wire wheeling, disassembly, replacing parts, installing gears and lockers and new brakes, slapping it all back together and THEN setting up new spring perches, steering, and shock mounts. If it was practically a bolt-in at 2k and you’re getting 44 strength in an already-narrowed package, it sounds like money well spent. Now I’m just waiting to see someone post their completed swap and provide a full write up. -Hônes

 

Shackletts' Axiom " There is no metal so strong, that it can withstand a weak mind" I know people that break Rockwells, perhaps you should consider 1. smaller tires, 2. Larger front axle, 3. smaller engine, 4. a mechanical throttle stop 5. Self restraint. Not in any particular order. LOL You are the only one that knows how you drive your Jeep, there are lots of good suggestions in this thread, you need to consider what you want to do with this Jeep, how you use it, and how much money/time/energy you need to invest. Good luck !

 

I called Fredricks near Hartselle Alabama and they want 1400 for the assembly. The hardest part to get with these seems to be a housing that fits exactly aside from the spring perch width. The housing alone was 600ish. I would rather have 30 spline stuff anyway so I might go that route. I haven't been able to find any dana 44 housings close to this price though it seems expensive compared to a rear housing.