Ronjenx, if you could grab a measurement of the passenger side shaft that would be amazingly helpful. It should all, in theory, be the same size as stock.

 

Front passenger side axle shaft measurement.

 

Also measure the distance to from tube to cross pin and see if it corresponds to how far the shaft goes in.

I can tell you that on new lockers the splines can be very tight. RCVs I usually have to use a hammer to get them to seat all the way. The real fun starts when trying to pull them out. I fabricated an RCV puller because of it.

 

Invest2m4 we measure the distance from the edge of the axle tube to the pin and put a mark on the shaft in that spot. It is without a doubt going in all the way and bottoming out.

Will measure the shaft when I get home and see how long it is, hopefully the issue is with the shaft, I don't wanna pull this axle again.

 

Ok, so i did the measurment and according to the image y'all gave me, my axle shaft is approx .5" too long. Any thoughts?

 

I just happened to think...
Mine is for the Dana 44 with the Rubicon locker. I know the shafts are different lengths on the rear 44 for Rubicon vs non-Rubicon.

What do you have for the diff in your front axle?

 

Uh..... it's the Ultimate Dana 44 axle. Not quite sure what it compares to as far as setup. It has 5.13 gears and an eaton e-locker.

 

Well, you can definitely cut the shaft and that's honestly how most aftermarket shafts are made. That said, you shouldn't have to and I don't think you have any interest in doing so.

Something isn't right here. You mentioned 4wheelparts and we know that they're selling UD44s at a loss. Or, so we think. What we know is that we can build a UD44 for less than Dana sells them. It could be that Trans is building them using the HD housing and using their own shafts. I'd be shocked if Dana sent out shafts not cut right. They follow OEM manufacturing requirements and a mistake like that would be very significant.

 

I have an OX locker in D44HD/J8 which is the same housing as the UD44 and I have used both stock front 30 spline Rubi axles and Rubi 30 spline RCVs

 

Sorry I don't have much to add, but subscribed to see the outcome of this thread. That would be incredibly frustrating.