Solid Axle, 2WD to 4WD

[colinrmitchell]

I started my work on converting my 1997 2WD to a 4WD. I got a high-pinion Dana 30 from the 'yard, no locking hubs/mechanism, Spicer U-joints. Tore it apart today, getting ready to regear it to 4.88:1. The plan is to rebuild the axle, then get it under the truck. Then I just need a transmission and a T-case, and I should be all set. Also, I'm looking at a Lock-Rite up front eventually (love it in the rear). I'll let you know how my build goes.

I'll be getting my parts from www.ballisticfabrication.com. I'll do a radius-arm/panhard setup, using heims on the ends of the radius arms, and bushings axle-side. I'll keep my SkyJacker coils for now (cheap bastard). The axle is pretty nice, 1998. I hope the project goes well. Feel free to give suggestions if you have done a setup before. I'm pretty much a SAS n00b.

 

[DieselSmoke]

so im guessing its going to be a daily driver?... but still why throw money at a dana 30? what size tires you wanna run? a locker will brake your d30 shafts eventualy you know right... and if theres no hubs its always going to be locked and if you cant unlock the hubs after you put in a locker in the front=no street driving

i would never put money in a dana 30, even just for street IMO

 

[colinrmitchell]

It's not my DD, it's mostly for trails/fun.

The locker will unlock around the turns, anyways. And that's gonna be farther down the road.

I won't be doing 4WD on the roads. And I'm only gonna run 33"s. I don't mash the gas or run crazy gauntlets. I'd rather not break shit than go crazy. But, I guess that's just me.

 

[86ford]

OK first off..... the d30 is always engaged unless you got a axle with the vac. disconnect (JUNK). not being able to disengage the front axle is the big down fall of the d30. as for t-case and such shoot me a PM. i have a t-case i mite be able to sell ya depending on what your looking for. d30's are better than a d28 but are roughly equal to a d35 in most cases.

86

 

[hitech_hick]

Honestly I wouldn't be concerned with the axle shafts or u-joints (they are the same size as the Ranger's) nor would I be concerned with the fact that it is a live axle (eliminates issues with the hubs). The biggest downfall of running a D30 is the size of the ring and pinion; short of sending it in and getting it cryo-ed (which would be a waste), there is no way of upgrading this week link. That said, good luck, and keep us posted with the build.



hick

 

[Evan]

Honestly I wouldn't be concerned with the axle shafts or u-joints (they are the same size as the Ranger's) nor would I be concerned with the fact that it is a live axle (eliminates issues with the hubs). The biggest downfall of running a D30 is the size of the ring and pinion; short of sending it in and getting it cryo-ed (which would be a waste), there is no way of upgrading this week link. That said, good luck, and keep us posted with the build.



hick

Agreed. Both are 27-spline axles, and can use a 5-760x u-joint. Weak link with the 30 is the R&P.

 

[4x4junkie]

Unless your truck is a Supercab, I think the D30 will be fine with 33s. Just try to avoid mashing the throttle (this would be how you'd strip the R&P gears).

 

[metalmacguyver]

So, now that we are done hijacking the thread, Any progress today?

 

[colinrmitchell]

Well, I got the nub on top of the pumpkin cut off, and another bracket for an upper link. I gotta wait until my buddy gets his torch put back together this weekend so I can take the coil seats off. Then I'll blast the axle, clean it up, and probably order the new coil seats. I'll be using one of these:

The constructive criticism is great. This is the first time I've done a project this intense, so I want to take it slow and make sure I do it right the first time. I'll probably post up a picture describing the set-up I want to do, and maybe you all can give me some help!

I'm going to a swap meet this weekend, hoping I can find a T-case. We'll see how it goes.

 

[DieselSmoke]

so I want to take it slow and make sure I do it right the first time.

IMO, then you better get a different front axle. i know for a fact after you wheel with a dana 30 for a while you will want to upgrade.

Its like building a drag truck and stroking the 2.9L motor

 

[F150hybred]

Looks like you and I are on the same page here Colin. I have pics of what I have done so far, and it seems we are a carbon copy of each other.
My pics are here---> http://s219.photobucket.com/albums/cc20/F150hybred/

 

[mhughes165]

idk...maybe its just me, but i really feel that the money could be put into a more productive swap(ie shorten a full width d44) but this is a argument that will go back and forth on here for a long time, i just want to ahve the opinions of guys that have put in there d30 and how its held up

 

[F150hybred]

Well, from what I have read and herd, if you keep it to a limit (tire size and engine power) the Dana 30 will do fine. If you start going with bigger tires (anything above a 33" tire) and bigger power, they will not last. Myself, I sat down before all this and came up with a list of what I expected and wanted from my truck when completed. The Dana 30 and 31" tires seemed to fit the bill. I don't plan on doing any "real hard core wheeling" just some semi remote access camping and trail running.
You gotta remember, I live in the prairies... the biggest hill we see here is an ant hill and it's all farm land. For me to get into any real nasty areas, I will have to travel some distance.

 

[hitech_hick]

idk...maybe its just me, but i really feel that the money could be put into a more productive swap(ie shorten a full width d44) but this is a argument that will go back and forth on here for a long time, i just want to ahve the opinions of guys that have put in there d30 and how its held up

I feel the same way, and I have gotten tired of arguing it, at this point I just let people be and let them find out for themselves. And who am I to judge, I have two XJ's, one lifted on 35's and one soon to be lifted for a DD, both running HP D30's and 8.8's.

Wheel it, break it, upgrade, repeat; damn it's a vicious cycle...



hick

 

[colinrmitchell]

I understand what you guys are trying to say. Maybe I should clarify some things.

The truck has the 2.3L, and the 7.5" out back. I already spent close to $400 on the locker in the 7.5, and, for now, I want to keep that axle in there. So I'm looking for something that'll match it in strength. I figured a D44 in the front with the 7.5" in the rear wouldn't be well balanced. Also, I figure that if I do want to upgrade to bigger axles in the future, it wouldn't be that difficult, just weld on new spring seats and stuff, and it should fit on without too much hair pulling.

I'm on a pretty limited budget, having just forked out $4500 for a semester for school, and I just picked up a part-time job for gas money, and odds and ends.

So this build won't be a weekend deal, but I will try to keep up with it.

And, finally, I will NOT use over 33" tires on these axles.