So I want to upgrade my front axle and as I research I'm just wondering how much stronger a trussed/C gusseted D44 is compared to the same trussed/C gusseted D30. I know the ring/ pinion is the weak link but I'm only gonna run 37's for the time being and the factory 44s are so expensive I feel like I'd be better off just going with a super duty 60 and the artec kit.
Anyway just wanted to get some thoughts on how big a difference there is between the 44 and 30 even taking into account cromoly axles. I want to go 4.88s as well and it's a DD that at this time doesn't get wheeled super hard.

 

The factory d30 and d44 use the same basic housing, same length, tube diameter, wall thickness, same c's. Stock or upgraded with the same truss/sleeves/gussets - there will be zero difference in external strength between them. Internally? The 44's gears are obviously better. Is a beefed up factory d44 comparable to the d60 you want to build? No. If you have the skills, build the 60.

 

so basically what your saying you can turn a dana 30 into a 44 by swaping the internals?

 

But the internals cannot be swapped. So, armor your 30 and if it breaks upgrade.

 

Because I'm not too smart on this, what's the issue? If I changed the shafts with D44 shafts and the innards for a D44 in a D30 housing, it won't go? Is it that the ring and pinion physically won't fit?

 

No, the center sections are a bit different. The 44 center is larger to accept the bigger gears, and I believe it is offset a bit more than the d30. (they use different length axle shafts). Was just saying that the d44 'housing' has no strength advantage over the d30.

 

I wouldn't waste any money on a D30 other then gussets. Running 37's is a recipe for disaster on that axle, so I would be saving for it's replacement.

 

It doesn't matter how much you armor the tubes on the d30, the R & P is still the weak point when you put higher gears in. That's why I'm waiting to regear until I can afford getting a d44. The same thing goes for people who put rcv shafts in. Why would you want axle shafts that are stronger than the pumkin? It's just going to destroy the expensive part of your axle if you regear and armor up a d30.

 

Just finished doing this. went to 4.88 with a beefed up front 44 and stuck 35 spline chromolys in the rear. Definitely makes you feel better after ripping the 30 out.