Jeep Wrangler YJ 1987-1995 by Don Alexander

Author:Don Alexander
Language: eng
Format: epub
Publisher: CarTech Inc.
Published: 2019-03-07T16:00:00+00:00

Steep climbs and extreme rock crawling require strong driveline components. The axle housings can be modified to work with large tires. Many options are available to the YJ owner.

Stock Jeep Wrangler YJ Axle Assemblies

The Wrangler YJ featured the Dana 30 front axle with an axle disconnect and the Dana 35 rear axle assembly. These axles worked well with the short, narrow tires on the stock vehicles. Increase tire size and the larger loads overstress the components.

The Dana 30 and 35 axle assemblies can be beefed-up by using aftermarket ball joints, using full-clip U-joints, sleeving the axle tubes, using trusses on the housings, using C gussets on the steering knuckles, and using aftermarket chrome-moly axles. Sleeves, gussets, and trusses require considerable fabrication and welding. If you have the skills to do this, it is likely worthwhile. But if you need to pay shop labor, there are other options to consider.

Front Axles

The Dana 30 front axle assemblies were found on all YJ models and years. They featured the high pinion design that is slightly stronger than the low pinon design. The high pinion uses reverse cut gears so that the power is applied to the drive side of the teeth rather than the coast side of the teeth.

Axles are 27-spline, 1.16-inch-diameter shafts with a 7.13-inch-diameter ring gear. All Dana 30 front axle assemblies use a vacuum disconnect rather than locking hubs. The vacuum disconnect is prone to failure, either making four-wheel drive nonoperational or leaving the front axles locked if the failure occurs while engaged.

The 5-260x U-joints are used on nearly all Dana 30 axles except for some 1995 versions, which used the 5-297x U-joints.

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