Front Axle - Roxor 44 Or Built Dana 30

Looking for advice on how to replace my dana 25 mostly due to poor turning radius, and frankly I don't like having to baby it. I don't intend on changing engine (v6), gear ratio (5.38), or going bigger than 33" tires. Jeep weighs about 3500lbs. I want a locker...although I am happy with current lunchbox in the front, I would prefer a selectable after having an E-locker in the rear for tight trails. I want to spend about $2-4k. My goal is to be reliable/enjoyable on remote, tight, moderate backcountry trails, not heavy rock crawling or highspeed bashing.

Option 1: Roxor 44 w/ 5.38 gears (19 spline inner, 10 spline outer, odd ring gear)

• Lunch box locker
• Lockout hubs
• Price $2500, could do all work myself
• Add $1200 for RCV shafts with 19/10 splines
• Pro- mostly click and buy, stronger axle tubes, knuckles.

Option 2: Dana 30

• Regear to 5.38
• Chromoly 30 spline shafts (30 inner/27 outer)
• Selectable locker
• Lock out hubs
• Price $3500, would take time finding axle housing and then drop it off at shop to build.
• Pro – shares spindles/hubs/bearings/lockouts with rear Full Float axle, similar size to Dana 25 for easy installation

I am leaning Option 2 since it gets me a selectable locker and is closer to size on my dana25 so swapping should be quick once axle is ready. But since my final drive is like 86.1 with sm465...I worry I am pushing the limits and think rather than pushing limits of 30, just get the 44.

 

I would support Option #2 simply because that's the route I went. Anything Roxer seems a bit futile since it's an orphan. I know, I know classic Dana 30 support may be dwindling, but I'd still count on it first.
I'm using a Powr-Lok with 4:88s. I have 33's and turning radius is great; only limited by the tire scrubbing the frame.
I did not upgrade to chromoly shafts, however. The RCV shafts are no longer available for the Dana 30, which was my long-term plan.
I would suggest an Eaton True-Trac instead of a selectable locker just to save a few more dollars.
I had one shop set up my R&P, and another shop custom fabricated a HD drag link and tie-rod.
Don't forget the caster shims if you go this route.

Find a few folks who have used the Roxor 44 to see if they're happy with it. I'm watching this thread closely.

I hope to see you in Silverton!

 

Option 2 is the way to go. Ultimately stronger than the Roxor option, and much less size and weight.

 

I run a 30 with stock shafts/ spline count and selectable locker. Rest of the drivetrain closely resembles yours. I don't baby it, no problems to date
#2 would be my option. If you are handy I think you can get a 30 gone through on the light end of your budget ( using stock shafts, personally don't think you need to upgrade)

 

What you currently have fits what your goal is, unless $2-4K is burning a hole in your shorts.

 

X4 on a D30. Easy to find parts for and is pretty much bolt in.

 

I also vote for the dana 30. If you are lucky some of the items you want might already be on the axle, usually the lockouts are almost always included in a used axle. And chromoly shafts are nice to have, they are not necessarily mandatory but are something you can upgrade over time do its less expense up front.

 

I literally swapped my D30 in one day.

http://www.earlycj5.com/xf_cj5/index.php?threads/141794/page-9

 

Spartan Locker Helical Limited Slip Differential Worm Gear Positraction Dana 30 Front 27 Spline 3.73 & Up (SL D30-4-27-LSD) https://a.co/d/doGh6cU
I have bought four of these now. Basically a tru-trac for half the cost.

 

Yep and I don't think the Roxor axle shafts are much, if any, stronger than the d25/d27 shafts. A well built d30 is just about as strong as a d44.

 

How about option 3?
Junkyard Dana 44 from Chevy truck or Wagoneer
DIY cut down and reweld the C's
Moser re-spline of the 30 spline inner shafts
Chevy stock 19 spline outers
Chevy spindles and disc brake calipers
Ford internal spline hubs (5x5-1/2 ) and rotors
Multitude of ratio and locker choices
Say you did it yourself and never worry again.
Last time I did it, I think about $2800, but you may pay for gear set up for a little more.

 

Not that I’m opposed, ( *checks notes at upcoming build plans and sees a pile of ridiculousness…) but what would be the benefit? The weak spot is still be the same 19 spline shafts and 1310 joints, no? Thats a lot of extra everything for the same weak points.

 

Bigger ring gear, bigger carrier, bigger shafts (30/19 vs 19/10 for the roxor), internal spline hubs, bigger and thicker tubes. Yes the 1310 joint is the weak spot, but I haven't broken one with 37's yet. I think, (for me), it boils down to-you do all that work and you still have a 30. Why not go a little further, and instead of being at the upper limit of its capability, have a little more beef, with mostly budget friendly junkyard parts, (no RCV's needed), that won't let you down? I dunno, just sounds like more fun that options 1 or 2.

 

This is helpful, thanks for input.
ill keep my eye out for a Dana 30 candidate. The chromoly shafts now (rather than if I break a stock one) are so I can hopefully just do it once and while they still make them for narrow tracks.
I can move my tracker disks brakes over to a Dana 30 (if I can only find drum versions) and my m38 cover as well, which can save some cost.

 

Cutting down axles are way beyond my skill set or available time to learn. But this beefy one showed up on Facebook near me…fun to dream.
https://www.facebook.com/groups/130188143846298/permalink/2384365241761899/?mibextid=6ojiHh

 

<private listing> or account required to view.

 

Oh, it was a ecgs builder front axle housing and knuckles with 1/2” thick tubes and giant metal bosses on the pumpkin.

 

WOW

 

Driver’s side drop and high pinion?
-Donny