I read somewhere here that the new ones are stronger. Any truth to that? What is stronger and how do you know? Is this true with the aftermarket Mopar ones?

 

I'm not sure, but I think there is a reason why they call them New Generation Dana 44

 

from what i have seen, the axle housing itself is thinner in our D44 than others.

 

The main difference is that the pinion gear is bigger. The Rubi has more axle splines and the axle joints have the 760s. also the outer axles have a higher spline count. I don't think the axle tubes are nececarily thiner but the front tubes seem to be busting on people near the track bar bracket welds. The rear D44 tubes are bigger than the front D44 tubes also. The issue with the front tubes seems like an metalurgy issue to me.

 

the rubicon does not have a 760 U-joint, its the same cap size but a longer joint.

the D30 HP has the 760 U-jpint.

 

It would be nice if somebody could prove this. Then maybe i could get my broken axle housing replaced under warranty. Like it should be.

 

i measured the thickness of my real axle housing with calipers. it was 1/16" thinner than a standard D44 from a TJ Rubicon. i haven't measured more than just mine though.

 

The new Petersen's 4 Wheel & Off-road has a write-up on this with pics. As mentioned, pinions on the JK axles are much bigger. On Rubicons the rears are 32 spline VS 30 spline for the TJ (I think non-Rubi JKs are still 30 spline though). The axle tubes are supposed to be bigger and thicker as well. FWIW the new D30 is supposed to be improved over the D30 in the TJ as well.