Looks like I've got a failed pinion bearing. Time for a master overhaul kit. Worst part of it is, the e-locker could be compromised as well, but the shop is still assessing the situation and I'm waiting for a call back.

QUESTIONS

1. I know guys have ARBs and love them, but has anyone replaced the rear Dana 44 factory e-locker with a Detroit? I'm on Northridge's site now and I can't even locate one.
2. *I should know this question, but can anyone tell me what my spline count is on this axle? I guess I can wait for my mechanic to pull it apart to confirm, but it should be a normal Rubicon D44, no? 30 spline (as opposed to the 27 spline D30 I've got in front)?

*There is some confusion about whether or not a Wrangler X with the optional Dana 44 locking rear end is the very same axle that goes under a Rubicon. It may be there are actually three distinct axle housings sitting around the JK assembly line: Dana 35, Dana 44 open, Dana 44 e-locker with a different spline count than the D44 open (the latter being destined for Rubicons). I don't know this for sure though, hence the epilogue.

 

I am pretty sure the rear D44 w/elocker has a 32 spline count. The bigger issue is it uses unequeal length shafts. If you switch to a different locker style you may need to purchase new shafts of equal length. My best advice would be to spend a little extra at this point and upgrade to the selectable locker of your choice and 35 spline shafts.

 

This is all I've ever seen, nothing about a 3rd axle type.

Non-Rubi
30 front 27 spline
44 rear 30 spline


Rubi
44 front 30 spline
44 rear 32 spline

 

Thanks.

Turns out, Jeep uses three different rear end housings: 35, 44 non-Rubicon, 44 Rubicon. Carrier and pinion (and bearings for each) are larger on the 44R than the non-R. Seems nonsensical, but it's true.

If like me you're an X owner with the $750 factory e-locker option, you're getting not just the e-locker, but you're going from a 30-spline 44 to a 32-spline 44.

The good news is, my e-locker isn't compromised. So it's going to require a master overhaul kit and I'll be good to go. Whew, this could have been ALOT costlier.