Dana 44 Gear Set

Difficulty 5/510–20 hrs$400–8001984-1990, 1991-1995, 1996, 1997-2001

Premium rear swap option. ZJ V8 Dana 44 (rare), TJ Rubicon 44 (popular), or aftermarket built D44. 30-spline (older) or 32-spline (Rubicon). Strong, ratios up to 5.38.

The Dana 44 is the canonical 'strong rear axle' for the XJ. Doesn't come stock on any XJ; sourced from a ZJ V8 (rare and short), TJ Rubicon, JK Wrangler (with bracket conversion), or aftermarket from Currie/Dynatrac.

Variants:

TJ Rubicon Dana 44 (2003-2006): 30-spline, 5x4.5 bolt pattern, lockable, ABS-equipped. Most popular XJ rear swap option. Pull from a junkyard TJ Rubicon ($600-1200) or buy aftermarket axleshafts after swap.
JK Dana 44 (2007+): 32-spline, 5x5 bolt pattern, larger. Stronger but wheel bolt pattern mismatch unless you also swap a JK front or hubs.
ZJ Dana 44 (V8 Grand Cherokee, 1993-1998): same width as XJ, 30-spline. Rare. The original XJ D44 swap before the TJ source.
Built aftermarket: Currie F9, Dynatrac ProRock 44. $2500-5000.

Gearing a Dana 44: similar to D30. Yukon, Motive, USA Standard. Ratios available 3.07 through 5.38 (5.38 may need a thick-pinion kit). $200-300 per set, $250-300 master kit.

The TJ Rubicon 44 swap is the most common XJ rear upgrade. With the locker already in the housing and the 4.56/4.88 ratios already in (some Rubicons came 4.10), it can save the regear step.

Bracket work: TJ axle uses different spring perch locations. Either weld new perches or buy a bracket kit (Crown or aftermarket).

Why it works

strong
deep ratios
Rubicon-source locker included

Trade-offs

donor sourcing
bracket fab

Tools required

dial indicator
marking compound
press
MIG welder (perches)

Parts

Part	Vendor	Est. price
Yukon D44 4.56 ring/pinion	Yukon	~$240
Yukon D44 master install kit	Yukon	~$280
TJ Rubicon Dana 44 (junkyard)	junkyard	~$900

Sources

{'title': 'TJ Rubicon 44 swap', 'url': 'https://www.cherokeeforum.com/f2/d44-rubicon-swap/'}

Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.