Bolt-in products should always be easy for the installer. It doesn't matter whether it's an axle set, air intake, or exhaust system, if you are gifted with a shred of mechanical inclination then "bolt-in" should mean you can install "X" part in your driveway. Last month we let you in on the new bolt-in JK-to-TJ conversion axles from Mopar and highlighted what makes these next-generation Dana 44 axles a major upgrade over the old style Dana 44s.
Ripping out your old axles...
Ripping out your old axles is the most time consuming process of the swap. Although it's only a few dozen bolts, you will need to take care when removing all of the miscellaneous tabs, lines, and hoses, since most pieces will be used again.
For this installment we've plucked out our '97 Jeep Wrangler's puny Dana 30 and 35 axle combo and rolled out the toolbox to see what it takes to put these next-gen Dana 44 axles in place. Since these were the first batch of next-gen Dana 44 conversion axles to hit the market, we enlisted the help of the veteran Jeep experts at Off Road Evolution to ensure the install went smoothly. While we had the help of the pros and a two-post lift, this doesn't mean you can't grab a buddy, floor jack, and spend a little time in the driveway over the weekend knocking out this bolt-in axle upgrade. Though this axle swap is extremely straight forward, you will need a few additional aftermarket items to complete it. Compiled here are some of the highlights and info that will provide all of the tech you need to toss in your new axle set.
How It Works
We've had the axles installed for a few months now and after piloting our '97 Wrangler over the road and through the Rubicon trail, we are very pleased with their performance. Since the Jeep is currently running 33-inch tires, the Dana 44 axles did get a few scrapes over the rocks, but they never received any significant damage. The on-road driving is leagues better with the selectable lockers, and off-road they engaged and disengaged quickly and work just like factory lockers should.
The Mopar conversion axles...
The Mopar conversion axles are designed to reuse your suspension's factory links. Our TJ was equipped with a Rubicon Express 31/2-inch short-arm kit. We didn't experience any problems or issues swapping axles with our aftermarket suspension system.
When you order your next-generation...
When you order your next-generation Dana 44 axles from Dynatrac (a performance axle specialist and authorized Mopar dealer), you have the option of upgrading them to Trail Series axles. This allows you to step up to Dynatrac's beefy differential cover and pick from a variety of gear ratios. We went with 4.88 gears so that our four-popper can get us down the road and trail more easily.
Though the larger JK calipers...
Though the larger JK calipers will accept your factory and aftermarket TJ brake lines, we opted to upgrade to a set of aftermarket steel braided JK lines from Rubicon Express (PN RE1530). This routes the lines in a more vertical and direct fashion. They bolt in place without any adapters or modification to your TJ's existing hard lines.
A Mopar wiring harness (PN...
A Mopar wiring harness (PN P5155359) is needed to control the 12-volt electronic lockers and plugs into the two axle connectors in the cast centersection. While you can tap into the locker's indicator signal for use with an aftermarket switch or...
... light indicator, we chose...
... light indicator, we chose to keep things simple with a set of Painless waterproof toggle switches (PN 80530). With our center dash unit removed, we fitted the toggles into our TJ's factory accessory panel and safety-wired them into place.
The factory lower steering...
The factory lower steering tie rod on our Jeep had been upgraded with a solid lower rod from a '93-'98 V-8 Grand Cherokee. This meant that the bar adjustment was only on the outer end of the axle. And though there was enough adjustment to allow our steering system to bolt in place, we decided to make a longer adjustment sleeve just to be on the safe side.
Since our '97 Jeep Wrangler...
Since our '97 Jeep Wrangler is equipped with the factory four-cylinder engine, the new high-pinion front axle didn't interfere with our exhaust. We are told that some late model TJs equipped with the inline-six may require exhaust modification to clear the front driveshaft.
For the rear brakes, we opted...
For the rear brakes, we opted for the pre-installed hard lines; since our '97 TJ was equipped with drum brakes from the factory, we sourced a new set of late-model emergency brake cables from Mopar. Be sure to specify the year of your Jeep before ordering from Dynatrac, as later model TJ's may only need an adapter.
It depends on how modified...
It depends on how modified or stock your Jeep is as to whether you will need a new set of driveshafts. We found that the new length and height of the high-pinion front 44 required a shorter front shaft, while the old rear shaft bolted right into place. Since our shafts had well over 120,000 miles on them, we swapped in a set of heavy-duty shafts from J.E. Reel.