EUREKA

I see. Thanks guys that's something to go on.

I need a couple more of these metal plugs in the floor

My door hinge pins on the drivers side are very sloppy. The pins are .247" and 0.249". Assuming they were exactly 1/4" new, they have seen very little wear. Unfortunately I seem to have no bushings whatsoever. What is the recommended fix for this problem?

Love those headlights, and the hood scoop! Awesome build so far, can't wait to see it finished.

Are the rear door strikes from 97-01 XJ's the same as the front door strikes?

Thanks. I actually had a tom woods drive line in my last jeep. I see the 242 sye is sold packaged with a tom woods drive line by rustys offroad. And I saw using summits website that its no problem finding truetrack nits for the Dana 44. Its valuable to know that it is not some kind of oddball version.

Of course.

Wow, that's way more lift than the thickness of the axle tube! Nevermind.

It's nice to hear something encouraging about the 242 because it does seem to fit my needs. Is there a brand of hack in tap sye that you recommend for the 242? I have only rebuilt 231's using Novak Adapter kits. I hadn't planed to lift it much, partly because I don't want to make it more difficult to use the bed. I think 2" spacers on the metric ton front coils for the front, and spring over for the rear. I'm not sure that would give an even lift though. I plan on upgrading the swaybar. Plan on new control arm bushings, and WJ control arms as well. I'm not aware of any factory clutch pack type LSD that are comparable to the truetrack in performance. I have seen some factory LSD perform very well when they are still newer, but not the same. Helical gear LS is far superior in my experience, especially once in the mud. Basically, if I can't find one for the MJ Dana44, I will not be using my Dana44 in this truck.

If it wasn't 100 degrees and choked with wildfire smoke, I'd be more tempted to travel to the big cities. A road trip maybe required in the end.

Oh ok I missed that. Thank you!

It's an option. In the past that has meant an 8 hour trip, one way but according to car-part.com there is a Dana44 ZJ 3.5 hours (178 miles) drive from me. Still, considering the gas money, my time, and the drive being notoriously unpleasant, I'm definitely interested in any kits that are available. What should the parts for the Dana44 rear disk conversion cost from a yard?

I live in a very rural area. There is one wrecker within hundreds of miles. The odds of me finding a ZJ with the Dana44 are basically none. In fact I've just called the wreckers and they have no ZJ's, XJ's or MJ's at all. (I forgot to ask about WJ's for the front brakes and steering parts, I'll have to call them back) I see there are some kits available for doing this conversion. Most are for the TJ or LJ, will these work for me? Any recommendations on this? Found this kit https://leedbrakes.com/i-23439388-rear-disc-brake-conversion-kit-with-maxgrip-xds-rotors-dana-35-dana-44-chrysler-8-1-4.html

I believe in the third post or so on this thread I said that out of ignorance I seem to have asked the wrong question. I'll explain what I'm after but I have to say this thread is interesting even if it's not exactly all targeted to my current goals. So here is what I need the truck to do; - A lot of driving on wet, curvy, hilly, highway. To this end I've even considered a 242 t-case, I have probably three 231's and at least one 242 laying around to rebuild. I understand the drawbacks of the 242 vs 231 but am not aware of any difference there may be in availability of aftermarket upgrades. Suspension or steering upgrades to improve handling on wet, curvy highway are of interest (I know its not a sports car). - Be able to easily travel over very steep grades with a "full load". I'm not sure what the weight of a "full load" is. I know that I regularly haul loads just over 1200 pounds according to the scales at the dump.) I also know that ZJ's and XJ's I've owned in the past had inadequate brake systems when full of camping gear (disk and pad upgrades certainly help but don't get me the performance I want) We're talking very steep grades, and the climb is not the problem. I do have some switches in the cab that allow me to control which gear my AW4 is in, and that helps. - Brake well while hauling a load. - Access work sites via sloppy, rutted dirt roads. My ZJ with 2" lift coils, 30" mud tires, 4.10:1 gears, and Detroit tructrack differentials was able to do this pretty adeptly, I just had to avoid ruts made by full size trucks. I'm not sure Eaton makes a truetrack for the MJ Dana44, and if they don't I'm not sure what I will do. I really loved the performance on and off road from the truetrack units.

Ive been there. I actually had a ps cooler on my ZJ for many years.

ok thanks!

lol, why not a Dana 80? I'm concerned about the weight of dana 60's seriously affecting the handling of my truck. A Dana 300 is interesting to me, honestly so is a T-18. I'm a bit concerned about the availability of Dana 300's. I don't recall actually seeing one in person, ever. I have no interest in a manual transmission for this truck.

Thanks for the parts list and info. What tie-rod ends would you have use, if they were available?

I was excited to see the Dana44 kit from Black Magic, https://www.shop.blackmagicbrakes.com/Dana-44-Rear-Disc-Brake-Conversion-Kit-w-Set-10-Bearing-Parts-Dana-44-Rear-Disc-Conv-w-Beaings.htm But the description says that it does not work on the XJ Dana44. As of now I'm thinking the WJ big brake and steering upgrade is for me for the front axle.

I was aware of the aluminum center section Dana44 from some V8 ZJ's, I didnt even think about that for upgrading the brakes on my MJ's Dana44. Unfortunately I live in a VERY rural area. There is only one auto wrecker in a radius of hundreds of miles. I think I'll see what they have in stock for ZJ's.

Awesome. I have a lot of reading to do.

The question I have is weather or not I can fit one that is the same or greater fuel capacity as the stock tank? Just by eyeball it looks possible. Of course I would fabricate a bombproof skid plate. I need to do some measuring.

The link in your signature is a goldmine Thank you!

Woo that's a lot of great info. I do plan to use the Dana44 that I have already on the rear. I'm just not sure that a Dana30 (with upgraded axle shafts) is strong enough for the front. Although I do see guys with massive tires wheeling them. So maybe a really sloppy, muddy road with a load doesn't require more than an improved Dana30, especially with 33" tires or less. My ZJ's Dana30 with truetrac never had any problems with the task, but of course the cargo capacity of the ZJ even with seats folded down and stuffed with tools is far less than the payload capacity of a truck.

Thanks, I'll check it out.