I have to say that I'm not a Jeep guy, but I'm quickly learning.

At work we are converting a 2008 Wrangler Sahara Unlimted 4 door 2wd 6 speed into a 4wd.

We have a stock used transfer case, transmission (which I realize we only need the output shaft) and a D44 rubicon front end. We still need the t-case linkage.

Anything else you can think of that we NEED to get it in 4wd? Crossmember is the same right? Just doesnt have skid plates.

We are installing a rugged ridge 4" lift that includes control arms and coils.

Oh...and the Rubicon D44 front end was involved in a fire. I havent got it in yet, its being shipped. I'm just wondering what all we should replace while we have it apart. I'm thinking pinion seal, axle seals, and maybe tie rod end boots. Do you think anything in the air locker was damaged?



Anybody done this before?

We are going to the Cavalcade of Customs with the truck to advertise out Jeep parts site.

Adam, that is a big undertaking...

A complete axle rebuild is in order. If you have steering issues, check the Teraflex steer mod for lifted JKs. It replaces steering knuckle for a more parallel alignment of the tie rods.

There are a couple of guys on the forum that may be able to answer your questions.

All the steering and brake parts are the same as your 2WD parts, if they come burnt on the used axle. All parts are the same from the ball joints out!

Make sure that the tubes are straight on the axle, they are notoriously weak, and the fire may have caused them to sag if it was hot enough. If you plan on wheeling it, there are tube reinforcement kits available.

The weak link with most lift kits is the track bar bracket that is welded to the rear axle, most lift kits extend the factory bracket, the side to side movement against the extended adapter tears the stock bracket off the axle! There are reinforcements for the bracket available in the aftermarket.

There are some electronic differences in the stability control system between the 2wd and the 4wds, I'm not sure, but you may end up needing to have a 4wd module fitted or maybe the aftermarket has some way of disabling the module. The 4wd module allows you to disable the system while in low range 4wd. The stability system is connected to the PCM to control the throttle, and to the ABS system to control the brakes. If I remember right, it's built into the ABS module, these are only available to be ordered to a specific VIN, and they have to be configured through the CAN Bus system, which makes swapping modules very difficult!

Also, to avoid problems, make sure that the steering wheel is perfectly centered after the lift is installed, if the wheel is even slightly off center after the lift and you drive it in a straight line, the stability control system will kick in, cutting the throttle and applying the brakes on one side to control what it thinks is an understeer condition.

A 4 inch lift may require driveshaft modifications.

Everything mechanical is a simple bolt up as far as the swap goes! The 4wd skid plates can be added, too.

Hope this helps!

Thanks for the info guys.

I'm doing this swap for my boss. This is really just a street Jeep to help promote his Jeep parts website, so honestly I don't think this thing will ever see any real offroading. Sad really....


New trans and transfer have been installed. We found a used front D30 that had a bad r/p and was in an accident, the D44 deal fell through. Tubes seem to be straight as the axle go in and out with no problem. Were putting in 410's. Everything bolted right up, no problems. We just need to go to the dealer and get the tcase shifter linkage.

I've got a rugged ridge 5" lift installed. F/R bumpers, rock rails, body "armor", bunch of lights, tube doors, and other stuff. 37's are to be installed in the next few days. I'll get some pics for you guys soon.

We're taking it to the cavalcade of customs to promote the website.