Jeep XJ Dana 44 Rear Axle For Sale: The Ultimate Guide to an Iconic Upgrade

Jeep XJ Dana 44 Rear Axle For Sale: The Ultimate Guide to an Iconic Upgrade jeeps.truckstrend.com

For enthusiasts of the venerable Jeep Cherokee XJ, few upgrades stir as much excitement and debate as the rear axle. While the XJ is celebrated for its robust unibody construction, solid front axle, and legendary off-road prowess, its stock rear axle options – primarily the Dana 35 and Chrysler 8.25 – often become the weakest link when venturing into more aggressive off-roading, larger tire sizes, or demanding conditions. This is where the mythical Jeep XJ Dana 44 Rear Axle enters the conversation.

Often considered the "holy grail" factory upgrade, the Dana 44 rear axle offers a significant leap in strength, durability, and aftermarket support compared to its common siblings. Finding a Jeep XJ Dana 44 Rear Axle for sale can be a challenging but incredibly rewarding endeavor, transforming your capable XJ into an even more formidable trail machine. This comprehensive guide will delve into everything you need to know about this coveted axle, from its importance and identification to finding, purchasing, and installing it.

Jeep XJ Dana 44 Rear Axle For Sale: The Ultimate Guide to an Iconic Upgrade

The Allure of the XJ Dana 44: Why It’s Worth the Hunt

The Jeep Cherokee XJ, produced from 1984 to 2001, is renowned for its affordability, simplicity, and immense aftermarket support. However, for those pushing the limits, the stock rear axles can quickly become a bottleneck:

• Dana 35 (D35): The most common rear axle found in XJs, especially later models without the tow package. It’s notoriously weak, prone to bending axle tubes, breaking axle shafts, and exploding differential carriers under the stress of larger tires (31 inches and above) and aggressive off-road driving. Its limited aftermarket support for internal components further compounds its limitations.
• Chrysler 8.25 (C8.25): A significant improvement over the D35, often found in XJs with the factory tow package or later model years. It boasts a stronger ring and pinion, larger axle shafts (especially the 29-spline version from 1997-2001), and a more robust housing. While capable for moderate wheeling and up to 33-inch tires, it still has limitations compared to a Dana 44, particularly in terms of pinion strength and overall robustness for extreme use.

The Dana 44 (D44), on the other hand, offers:

• Superior Strength: With a larger ring and pinion, a more robust housing, and typically stronger axle shafts (30-spline compared to the D35’s 27-spline or C8.25’s 27/29-spline), the Dana 44 is significantly more durable. It can confidently handle 33-inch, 35-inch, and even some 37-inch tires with proper upgrades.
• Extensive Aftermarket Support: The Dana 44 is one of the most widely used axle designs across various vehicle platforms, leading to an enormous aftermarket for lockers, gears, chromoly axle shafts, disc brake conversions, and trussing kits. This allows for highly customized builds tailored to specific off-road needs.
• Direct Bolt-In (for XJ specific D44s): The factory XJ Dana 44 is a direct bolt-in replacement for your existing rear axle, meaning no complex fabrication, welding, or custom mounts are required. This makes the swap relatively straightforward for those with basic mechanical skills.
• Peace of Mind: Knowing you have a stronger axle under your rig provides immense confidence when tackling challenging trails, reducing the risk of costly and inconvenient trail breakages.

Identifying the Elusive XJ Dana 44

The factory XJ Dana 44 is a rare gem. It was primarily offered in 1987-1989 Cherokee XJ models that came with the factory tow package, and sporadically in a few early 1990s models. It was never a standard offering across the board. Its scarcity makes identification crucial to avoid buying the wrong axle.

Here’s how to identify a genuine XJ Dana 44:

1. Differential Cover Shape: The most obvious tell-tale sign is the differential cover. The Dana 44 has a characteristic flat, somewhat octagonal shape with 10 bolts. In contrast, the Dana 35 has a more oval shape with 10 bolts, and the Chrysler 8.25 has a slightly rounded, almost square shape with 10 bolts.



2. Casting Numbers: Look for a "44" cast into the housing itself, usually on one of the reinforcing webs near the differential cover. While this is a strong indicator, always combine it with other identification methods.
3. Axle Tube Diameter: The Dana 44 typically has larger diameter axle tubes than a D35. While harder to measure accurately without comparison, it’s another visual cue.
4. Spring Perch and Shock Mounts: Crucially, ensure the axle has the correct leaf spring perches and shock mounts for an XJ. These should be welded onto the axle tubes at the correct width and angle for a direct bolt-in fit. Be wary of Dana 44s from other Jeeps (like Wranglers – TJ/YJ, or Grand Cherokees – ZJ/WJ) or other vehicle manufacturers, as they will require significant modification to fit an XJ.

Where to Find a Jeep XJ Dana 44 Rear Axle For Sale

Given their rarity, finding an XJ Dana 44 for sale requires patience, persistence, and knowing where to look.

1. Salvage Yards/Junkyards: This is often your best bet and where most XJ Dana 44s are sourced. Visit local "pull-a-part" or traditional salvage yards. Be prepared to crawl under many XJs. Focus your search on 1987-1989 models, and look for vehicles that appear to have been equipped with a factory tow hitch.
2. Online Marketplaces:
   • Facebook Marketplace/Groups: Many local and national Jeep groups on Facebook are excellent resources. Post "want to buy" ads and regularly search for "XJ Dana 44," "Cherokee D44," or "Jeep 44 axle."
   • Craigslist: Similar to Facebook, but often more localized.
   • eBay: Less common for complete axles due to shipping costs, but occasionally a local seller might list one.
3. Dedicated Jeep Forums: Websites like NAXJA (North American XJ Association) and Jeepforum have active classified sections where members often sell parts. These forums are excellent because sellers are typically knowledgeable and understand what they’re selling.
4. Specialized Axle Shops/Off-Road Fabricators: Some shops that specialize in Jeep builds or axle assemblies might occasionally have an XJ Dana 44 for sale, either as a core for rebuilding or already rebuilt. Expect higher prices here, but also potentially a higher quality, ready-to-install product.
5. Word of Mouth/Local Clubs: Network with local Jeep clubs and off-road enthusiasts. Someone might know a guy who knows a guy with one sitting in his garage.

What to Look For When Buying an XJ Dana 44

Once you’ve located a potential XJ Dana 44, a thorough inspection is paramount. A cheap axle can quickly become expensive if it requires extensive repairs.

1. Overall Condition:
   • Rust: Surface rust is common and generally not an issue. Look for deep, penetrating rust that could compromise the structural integrity of the housing or axle tubes.
   • Bent Tubes: Use a long, straight edge (like an aluminum level) along the axle tubes. Any noticeable gap or bend indicates a problem. A bent axle tube will cause premature tire wear and can be difficult and costly to straighten.
   • Cracks: Inspect the welds around the spring perches, shock mounts, and differential housing for any cracks, especially if it looks like it’s seen heavy off-road use.
2. Differential and Gearing:
   • Pinion Play: Grab the pinion yoke and try to move it up and down, side to side. Excessive play indicates worn pinion bearings, which will need replacement. Some rotational play is normal.
   • Gearing: Ask the seller about the gear ratio. Common factory ratios were 3.55, 3.73, and 4.10. If you’re running larger tires, you’ll likely want to re-gear to 4.10, 4.56, or even lower (numerically higher) ratios anyway, but knowing the current ratio helps with planning.
   • Differential Fluid: If possible, ask to inspect the differential fluid. Milky fluid indicates water intrusion; metallic flakes suggest significant internal wear.
   • Locker/LSD: Most factory XJ D44s did not come with a locker or limited-slip differential (LSD). If the seller claims it has one, verify it.
3. Axle Shafts:
   • Check for any signs of bending or twisting, especially near the splines.
   • Inspect the wheel studs for damage.
4. Brakes:
   • Most XJ D44s came with drum brakes. Inspect the condition of the drums, shoes, and wheel cylinders.
   • Many owners convert to disc brakes (e.g., using ZJ, KJ, or WJ components), so factor this into your budget if it hasn’t been done.
5. Mounting Points: Ensure the leaf spring perches, shock mounts, and sway bar mounts are all intact, straight, and not compromised. These are critical for a bolt-in swap.
6. Price Negotiation: Prices vary wildly based on condition, location, and urgency of sale. Be prepared to negotiate, especially if the axle requires rebuilding or new components.

The Installation Process (Overview)

While a direct bolt-in, swapping a rear axle is a significant mechanical undertaking.

1. Gather Tools: You’ll need a good set of sockets and wrenches, a breaker bar, jack stands (at least 4), a floor jack, penetrating oil, a torque wrench, and potentially a grinder for seized bolts.
2. Safety First: Always work on a level surface, use sturdy jack stands, and chock your wheels. Disconnect the battery.
3. Disassembly:
   • Remove rear wheels.
   • Disconnect parking brake cables.
   • Unbolt brake lines and brake proportioning valve (if applicable).
   • Disconnect the driveshaft from the pinion yoke.
   • Unbolt shock absorbers from the axle mounts.
   • Remove U-bolts securing the leaf springs to the axle perches.
4. Removal: Carefully lower the old axle and roll it out from under the vehicle.
5. Installation:
   • Roll the new Dana 44 into place.
   • Align the leaf springs with the perches and install new U-bolts (always use new U-bolts!). Torque to spec.
   • Reconnect shock absorbers, driveshaft, brake lines, and parking brake cables.
   • Fill the differential with fresh gear oil of the correct weight and type.
   • Bleed the brakes thoroughly.
6. Final Checks: Double-check all bolts for proper torque. Test brake function before driving.

Challenges: Seized bolts, rusted brake lines, difficulty aligning leaf springs, and bleeding brakes are common hurdles. If you’re unsure, consult a professional or a more experienced friend.

Common Upgrades and Modifications

Once you have your XJ Dana 44, you’ve opened the door to a world of performance upgrades:

• Re-gearing: Essential for matching larger tires (33+, 35+) to your engine’s power band. This improves performance, fuel economy, and reduces strain on the drivetrain.
• Lockers: Install an automatic locker (e.g., Detroit Locker, Spartan Locker) or a selectable locker (e.g., ARB Air Locker, Eaton E-Locker) for maximum traction on the trail.
• Chromoly Axle Shafts: For extreme off-roading, chromoly shafts provide superior strength over stock steel shafts, reducing the risk of breakage.
• Disc Brake Conversion: Swapping the stock drum brakes for disc brakes (often using parts from a Grand Cherokee ZJ/WJ or Liberty KJ) provides better stopping power, improved heat dissipation, and easier maintenance.
• Trussing: Welding a truss (a steel reinforcement structure) to the axle housing can further strengthen it, preventing bending under extreme loads.
• Differential Cover: An aftermarket differential cover (e.g., ARB, G2) can offer increased fluid capacity, better cooling, and enhanced protection against impacts.

Potential Challenges and Solutions

• Availability: The biggest challenge is finding one. Be patient, cast a wide net, and be ready to travel for a good deal.
• Condition: Many axles from salvage yards will require new seals, bearings, and potentially a full rebuild. Factor this cost into your budget.
• Price: Prices vary wildly. A bare, rusty housing might be $200, while a complete, good-condition axle could be $800-$1000+, and a rebuilt one even more.
• Shipping: Axles are heavy and bulky. Shipping can be expensive. Prioritize local pickup if possible.

Legal and Safety Considerations

Modifying your vehicle’s axles can impact its safety and legality.

• Proper Installation: Ensure all components are installed correctly and torqued to specification. Brakes must function flawlessly.
• Brake Proportioning Valve: If you switch from drums to discs, you may need to adjust or replace your brake proportioning valve to ensure proper front-to-rear brake bias.
• Local Laws: Be aware of any local or state laws regarding vehicle modifications, lift heights, and tire sizes.

Jeep XJ Dana 44 Rear Axle Price Table (Estimated)

Please note that these prices are highly variable based on condition, location, included components (gearing, locker, brakes), and seller.

Item/Condition	Description	Estimated Price Range (USD)	Key Factors Affecting Price
Bare Housing (Core)	Rust, bent tubes, no internals, missing shafts/brakes. Primarily for rebuilders or fabricators.	$100 – $350	Severity of damage, presence of rust, local availability.
Used, Complete (Stock Condition)	Pulled from a junkyard XJ, original gearing (e.g., 3.55, 3.73), drum brakes, functional but may need seals/bearings.	$400 – $850	Overall condition (rust, straightness), mileage, presence of any internal issues, location, seller’s urgency.
Used, Complete (Minor Upgrades/Rebuilt)	Good condition, might have new seals/bearings, possibly re-geared, or converted to disc brakes. No locker.	$800 – $1,500	Quality of rebuild, specific gear ratio, inclusion of disc brakes, condition of axle shafts.
Used, Complete (Performance Ready)	Rebuilt, new bearings/seals, desired gear ratio, chromoly axle shafts, likely disc brakes, possibly an aftermarket locker (e.g., ARB/Detroit).	$1,500 – $2,500+	Brand/type of locker, quality of components (e.g., chromoly shafts), professional rebuild, warranty (if any).
New/Custom Built (Bolt-in Replacement)	Rare for XJ D44s directly. Usually a custom-built Dana 44 or similar axle (e.g., Ford 8.8) adapted for the XJ.	$2,000 – $4,000+	Builder’s reputation, specific components chosen (gears, locker, shafts, brakes), labor costs. Not a "stock" XJ D44.

Frequently Asked Questions (FAQ)

Q1: Is the XJ Dana 44 a direct bolt-in replacement for my Dana 35 or Chrysler 8.25?
A1: Yes, if it is a factory XJ Dana 44. The spring perches, shock mounts, and overall width are correct for a direct swap. Dana 44s from other Jeep models (like Wranglers) or other vehicles will require significant fabrication.

Q2: What years did the XJ Dana 44 come in?
A2: Primarily 1987-1989 Cherokee XJs equipped with the factory tow package. Some rare instances in early 1990s models as well.

Q3: How can I tell if an axle is a Dana 44?
A3: Look for the characteristic 10-bolt, somewhat octagonal differential cover with a flat bottom. There will also often be a "44" cast into the housing.

Q4: Do I need to re-gear my XJ Dana 44?
A4: If you plan to run larger tires (33 inches or more), re-gearing is highly recommended. The stock XJ Dana 44 typically came with 3.55, 3.73, or 4.10 ratios. Matching your gear ratio to your tire size restores power, reduces drivetrain strain, and improves drivability.

Q5: Can I put disc brakes on an XJ Dana 44?
A5: Yes, and it’s a very popular upgrade. Common conversions involve using rear disc brake assemblies from a ZJ (Grand Cherokee), KJ (Liberty), or WJ (Grand Cherokee). This provides better stopping power and easier maintenance than drum brakes.

Q6: What’s a good price for an XJ Dana 44?
A6: A complete, used XJ Dana 44 in good, usable condition typically ranges from $400-$850. Prices vary greatly based on condition, location, and included upgrades (like re-gearing or disc brakes). Be prepared to pay more for axles that have been rebuilt or upgraded.

Q7: What’s the main difference between the Dana 35, Chrysler 8.25, and Dana 44?
A7: The main difference is strength and durability. The Dana 35 is the weakest, followed by the Chrysler 8.25 (a decent stock axle), and the Dana 44 is the strongest of the three factory XJ options, capable of handling more abuse and larger tires.

Conclusion

Acquiring a Jeep XJ Dana 44 Rear Axle for sale is more than just buying a part; it’s an investment in your Cherokee XJ’s longevity, capability, and your confidence on the trail. While finding one might test your patience and investigative skills, the payoff is immense. A properly sourced and installed Dana 44 transforms your XJ into a far more robust and reliable off-road machine, ready to tackle challenges that would leave lesser axles in pieces. With the right knowledge, a keen eye for detail, and a bit of perseverance, you too can secure this legendary upgrade and unlock the full potential of your iconic Jeep Cherokee XJ.