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Hey all,

I just picked up a 2004 Rubicon (after rolling my 07 Unlimited! :evil:) and I’m planning my build-up, but I admit I don’t know a ton about the Dana 44’s that come under the Rubicon. Anyone have clues as to their weak links (IE, thin-walled axle housings, C-clip shafts, crappy locker issues, etc.). I’d like to plan my build smart. It’s going to serve daily driver/moderate to heavy trail use with a 35” or 37” tire. I spend most my time on the rock in So. Cal.
 

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Fronts have a D30 size stub shaft still. Front is a low pinion so you are on the coast side of the gear. The stock lockers are not that strong. I've seen several killed with a 35" tire running east coast trails. Also the front inner-C's have been known to bend and I believe there are a few folks on this forum that have bent the front housing. A 35" tire I have seen break Rubi front 44s and the locker in the rear.

Otherwise the rear axle is fairly decent. Disc brake D44, similar to the Rodeo D44s really.
 
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