Tips for '06 Rubicon axles into a '01 TJ

[JpPassenger]

We wrapped up the swap this afternoon. The only other gotcha we encountered was that the D44 is considerably longer than the D30 we pulled. The D30 was about 10" from axle centerline to centerline of the U-joint. The same measurement for the D44 was about 13". The front driveshaft definately needs to be shortened. We chose to have 2" cut out based on measurements we took at full droop and full stuff, compared to the collasped length of the driveshaft. We have a long arm lift, so the slip joint travel is not big.

The parking brake cables from the rear D44 drum brake assembly wouldn't work on the Rubi D44 disc brake assembly. The brake cable for the drums has buttons on each end, while the disc cable has a button on one end and an eye on the other. The cables are on order as well.

We still need to determine whether we will need a new brake proportioning valve.

Otherwise, it was a pretty easy swap with a couple strong freinds and a jack.

Considering the cost in parts and labor to upgrade our original D30/D44 combo with new gears, all-around discs brakes and selectable lockers, I think we came out even, or just slightly ahead.

[JpPassenger]

Thanks a bunch!

Now, where shall I mail your beer?

KI6BQM

[goodtimes]

I'll need to wire up the compressors and the locker request/sense leads myself in the near future. I wish there were some schematics or pin-out diagrams for the compressors and the locker sense connectors out on the web. Otherwise, I'll have to buy a factory manual for this purpose.

Please stand by......


OK, this is info on the '03s. I doubt they have changed any of this between '03 and '06, but it is possible.

[JpPassenger]

Thanks to CJBrian, I was fortunate to come across a pair of D44's from an '06 Unlimited Rubicon, and will be putting them into our '01 TJ this weekend.

The axels were complete, and include the compressors, hoses, underbody wiring, disc brakes and calipers.

I've already gotten the 1310/1330 combo U-joints.

Are my parking brake cables (for drum brakes) going to work with the discs, or will I have to get new ones. Looking at the illustrations in the factory manual, it looks like the same retainer/hook & eye setup, but I'm hoping someone can share what they've learned before we get the drums off.

I'll need to wire up the compressors and the locker request/sense leads myself in the near future. I wish there were some schematics or pin-out diagrams for the compressors and the locker sense connectors out on the web. Otherwise, I'll have to buy a factory manual for this purpose.

Can anyone think of any other potential gotchas I may face this weekend?

I plan to post a write-up on the swap afterwards.

Thanks a bunch,
Greg