I am currently running a d44 in the rear which I am perfectly happy with. However, my front axle is the stock d30. Right now I have 33" tires and do light wheeling which is fine for what I have, but I am either going to go up to a 35" or a 37" tire, and my question is should I build up this axle or go ahead and swap for a d44? Is one recommended over the other depending on the tire size? As soon as I get new wheels, my wheeling will go way up
Thanks in advance

 

Many will say the limit for the D30 is 35's, especially when you start to add stress to it by adding steeper gears or lockers. I ran 35's on my D30 with no issue, but I would add gussets if you plan to wheel.

37's will work on a stock D30 if you stay off the trails. I wouldn't recommend running a D30 with 37's under any off road condition, Most will say a dana 44's max wheelable size is a 37.

Save yourself the headache and get the 44.

 

If you can afford it, the D44 will be the best long term option for either size tire. If you do decide to keep the D30, I would reinforce it and stick with 35's.

 

Alright so sounds like it'd be best to do 35s, so gussets? Truss? Anything else? Any recommended brands?

 

Keep in mind a stock D44 front will have the same inner Cs and axle tube as a D30, the only difference is the pumpkin/internals. So unless you get a built aftermarket D44, you will inherit some of the weakness of the D30. I gusseted and sleeved my D30, went with RCV axles and ARB locker and run 35s comfortable off road.

 

So you're running a d44 axle in the 30 housing?

 

If you are thinking about 37's, plan on kicking yourself in the ass for wasting money on 35's and d30 upgrades.

 

No, they are basically the same housings. The d44 just has a larger center section to fit the bigger d44 gears. Same tube diameter and thickness, same ends/c's, same brakes, they even use the same outer axle shafts. (the difference is the inner shafts and the r&p/carrier/locker)