Improving Dana 44 stub axles

[FAT CAT]

I've been snappin' the outer stub axles on my Dana 44; first a stock one & now a Yukon Chromo one.

I've got two options to upgrade:

First would be to get some Alloy USA chromo stubs which most people say are better and stronger than the Yukons or Superior, but how much stronger is a guess...They are 19 spline outers so I can use the new Superwinch hubs I just bought. They run 140 each stub axle...

Second option is to get some of the new 30 spline chromo Stub axles that Superior makes. They are 140 each too. These are Chevy length so to run them I need to cut them down and machine a c-clip grove. I will also have to enlarge the spindle a bit to fit them. I'd need to get new locking hubs too...

The 30 spline's are cut shallower than the 19 spline making the axle diameter larger & stronger than the deeper cut 19 spline axles.

So, what do you think would be the better way to go?
Let me know...

 

[Stic-o]

Are the Yukons warrantied?

Are the Alloys warrantied?

What back spacing are you running? This could be putting some added stress.

Over all I would say go 30 spline. I'm sure someone could make some to fit your truck. Maybe currie or something

 

[Dannyboy]

where are you snapping them? Is the splined area an issue, if not, I wouldn't spend money on changing that.

I ran the warn heavy duty shafts on 37s with Ox Joints, I did break one, but it was covered under warranty. http://warn.iwebcat.com/_Members/lookups/partdetail.asp

I purchased this setup because the guy who set up my gears claimed to be running a V8 in a jeep on 42s and ran it pretty hard never had any breakage. Not sure what to believe, and I know with you running 40s on a pretty built Explorer might have the same issues you currently are having.

 

[DB_1]

From what i've read the Yukon stuff just doesn't hold up and that's the case for the D60 guys too.

I've got Superior inner's and outers with Longfield joints and not one problem so far in almost 2 yrs now.

I think you are really beyond the limits of the D44 running 40" tires and need to step up to some beef D60 or 609 hybrid

 

[FAT CAT]

They are snapping in the middle of the shaft.

I know the Dana 44 is not the best for me but I'm gonna try & keep it in for a while. When these tires need replacing, I'm going to go back to 37's

I'm also thinking about cutting the body off & making it a buggy thing again At the event we just had, a friend had his 4Runner chopped down to just the frame and tube for the cage & it worked better. I think cutting the body off will shed a TON of weight & ease the strain on all the running gear, as well as making it a lot less tippy.

I'll need to get my van ready for towing & get the trailer together first...

 

[RangerX]

Have you noticed a pattern to when they are breaking? Like, wheels turned all the way, all the weight on the front wheels, etc?
Do you have a selectable front locker?

You ARE running 40's on a D44. Maybe just drive a little less agressively?

 

[FAT CAT]

Have you noticed a pattern to when they are breaking? Like, wheels turned all the way, all the weight on the front wheels, etc?

First one broke backing up slowly, wheels straight...


Do you have a selectable front locker?

Not anymore, I have an Aussie up there

You ARE running 40's on a D44. Maybe just drive a little less agressively?

Well what fun would that be?

Here is a picture of the shaft difference from the 19 spline to the 30 spline.

 

[4x4junkie]

That looks like a 27 spline stub, not 19

(guess it still would be pretty close in size though)

 

[sn0border88]

Get the chevy 30 spline stubs, replace your outers and that scary steering setup with a real histeer using chevy knuckles and spindles/ford hub and rotor and live in happy harmony.