Here is the info that I have so far...

Isuzu Axles
2nd gen trooper 12 bolt is 62" WMS-WMS

Jeep Axles
1979 wagoneer is perfect for SAS. 61.5" wms to wms.
1978 and 1979 where the only two years that still had passenger side drop and used the big bearing spindles.
1974-1976 were nice becuase of the flat top knuckles, but used the small bearing spindle.

Chevy Axles
Dana 44 - 1971-1980 - Dana 44 open knuckle.
(note: pre '73s had small 260x axleshaft u-joints. These are the same size as Dana 30s).

5.38's are available

All 3/4 ton axles after mid-'78 used internal locking hubs retained by locking rings.
After 1980 all 3/4 ton chevy front axles were 10 bolt...?

~67" WMS...?


Ok, so my reasoning is this. I can obtain a Wagoneer axle pretty easily but I can't see lifting my truck anymore and keeping the same axle width. I am planning on running 37/38's which is just about the limit of the Dana 44 with no modifications. I want to retain the same bolt pattern as the rear Isuzu 12 bolt. Dana 44's are about 200-250 lbs lighter than the Dana 60.
So here are my questions...
When searching for an axle online is there anyway that I can determine the difference between a truck with a 44 and one with a 10 bolt?
Which dana 44's had 6 lug and which had 8 lugs?
Can I simply swap in flat top knuckles that I find on eBay to a Dana 44? I know that almost all chevy axles have the driver side flat top.

I've been doing research for the last week and now I'm completly confused. Hopefully someone can give me a link that I may have overlooked or answer some of my questions to clear it up for me. Right now I'm pretty much <img src="/forums/images/graemlins/confused.gif" alt="" />

here is some good info here

http://coloradok5.com/specs.shtml#1991

My rodeo has a Cherokee Cheif axle much wider than the wagoneers close to a fullsize chevy axle

I agree the wider axle can help you from rubbing with big tires and smaller lift.

Might wanna dial down your target axle size there. 37-38s are pushing it for a rig of that weight. For the dana 44 and the 12 bolt. 35-36s would be a lot safer. Other than that, your info looks good.

With the Chevys, IIRC, there is a half ton version and a 3/4 version. The half ton has 6 lugs, the 3/4 has 8. The 3/4 also has larger bearings, larger brakes and thicker walled tubes. I would go with this axle for your trooper. Most rigs come with a front axle a couple inches wider than the rear, better tracking and turn radius that way.

1974-1976 were nice becuase of the flat top knuckles, but used the small bearing spindle.
big bearing vs small only becomes an issue if you're looking to upgrade to the 8-lug spindles, which require the larger bearing. I know plenty who run the small bearing D44's and I've never heard of a spindle breaking.

All 3/4 ton axles after mid-'78 used internal locking hubs retained by locking rings.
don't think this is always true. I had a '79 3/4-ton D44 that used external hubs.

After 1980 all 3/4 ton chevy front axles were 10 bolt...?
i don't know that there was a 3/4-ton 10-bolt. I think all 3/4-ton's were D44s.

I am planning on running 37/38's which is just about the limit of the Dana 44 with no modifications.
well, this is about the limit of a D44, *with* modifications. you won't run a stock one reliably at this size, you'll need CTMs and alloy shafts to really secure it.

When searching for an axle online is there anyway that I can determine the difference between a truck with a 44 and one with a 10 bolt?
visually, the two look very different. the insides are different as well I believe, spline count, ring gear diameter, etc. Also, i'm pretty sure Chevy only used D44s in the 70's and went to the 10-bolt in the 80's.

Which dana 44's had 6 lug and which had 8 lugs?
1/2-ton = 6-lug, 3/4-ton = 8-lug

Can I simply swap in flat top knuckles that I find on eBay to a Dana 44? I know that almost all chevy axles have the driver side flat top.
yes. *all* 4wd chevy's had a flat top drivers side due to their unique steering design. Chevy driver's side will be milled and drilled and ready to go, but all passenger side flat tops will need work before they're ready to bolt an arm to.

-Rob

the 12 bolts from the 2nd gen trooper with fender flares they are a few inches wider right? if that is correct, and a widetrack FSJ d44 is around 64"-ish that would work well for you. or you could cut down a chevy d44 to fit a waggy long side and end up around 63-64"

And I will also echo what others have said. to reliably run any tire over 36" you will want alloys and upgraded u-joints. not to mention you will want to keep an eye on your balljoints.

I am not planning on going to larger than a 36 until I can get some bling into my d44.

my fiance's uncle blew his 9" ford and an axle shaft on his Dana 44 in his 79 bronco doing what I would call moderate wheeling no full throttle it was slow rock crawling. it had a 351 with a manual and 35's.

Now since the isuzu's are pretty gutless unless you swap motors how can you bust axles with no power.

Its called gear reduction... and in terms of crawlin, the cubic inches of your motor doesn't necessarily relate to how easy it is to break things... especially with lower gears options out there now adays. Trust me, a Suzuki Sammy has enough power to tear parts up under the right conditions... not having a big block doesn't preclude you from the break down club.

-Rob

This is true. A buddy of mine has Toyota mini-truck axles under his Samurai with 150:1 crawl ratio and has eaten 2 axle shafts and 1 R&P set that I know of with 35's. This is with the stock 65-ish hp engine. He couldn't keep OEM-level parts alive after putting on 37's. Off-roading also introduces a lot of stress on a drivetrain that street trucks just don't see. Lots of quick changes in weight distribution, grabbing and losing traction, getting tires wedged in crevices, etc. I'd say 35's are the working limit on a stock D44 under an Isuzu that gets wheeled. Anything larger and its a good idea to upgrade shafts and u-joints or get familiar with your local Pick-n-Pull. CTM stuff is probably the strongest and definitely big bucks. There are plenty of options out there that provide a big upgrade over stock without the CTM price. Alloy USA axles with Longfield Superjoints can be had much cheaper than CTM stuff and still carry a 10 year warranty.

Thanks for the link to the Coloradok5 website. Very informative.

Mike, IÆm trying to retain the rear Isuzu 12-bolt because it already has 5.38Æs and a limited slip. Because of this I would want the 6 on 5.5 for the front too. I guess IÆll have to swap out the hub/rotor and all that to get the 6 lug.

Rob, 37Æs would be pushing it for the D44 with modÆs? I guess if I get the CTMÆs and alloy shafts then I would be approaching the price of a stock D60, but IÆll still have the advantages of the D44 like lighter weight and a smaller pumpkin.

In the question about searching for an axle on line I was referring more to the body style than the axle. D44Æs are easily distinguishable from a 10-bolt. The coloradok5 website that was given shows the K5Æs going from D44Æs only to a mix of D44 and 10b in 1977, then exclusively 10b in 1979.

Paul, thanks for the info. I have a 94 which was the last year of the 2nd gens that didnÆt have flares. I havenÆt physically measured my truck but IÆm assuming the rear is right at 61.5ö. So either way IÆll want to run spacers. If I get 2ö spacers that would put me at 65.5ö, so a front axle of 67ö would be desirable, if for nothing else than the wider stance. And here in Texas I havenÆt found anything strict about tire/fender coverage so I should still be in the green.


Ok, so here are my new questionsà
Does the coloradok5 website, which was specific to k5Æs, also refer to ¥ ton trucks, or is that something completely different?
What is involved in swapping a ¥ ton-8 bolt lug pattern to a 6 lug?
Would the Isuzu 12 bolt stand up to 37's?

Thanks for everybody's input/info so far. I really appreciate it because I wouldn't be able to get this information anywhere else. <img src="/forums/images/graemlins/cheers.gif" alt="" />

I believe Houlster's running 37s on his 12 bolt.

Richard <img src="/forums/images/graemlins/patriot.gif" alt="" />