Dana 44 breakage

[coyote72]

After recently twisting the splines off of the short dana 44 axle for the third time in less than a year, I am thinking about going to chromoly. I am running an aussie locker in the front with 33" tires. I am thinking of just doing the one side so the longer side will act as a 'fuse' and break before the carrier or ring gear. What have you guys done? Any recommendations on manufacturer, or a brand to stay away from?

[obijuan]

the short side will always break first all things being equal, it has less shaft length to twist before shear. i suggest both sides at one time.

you should plan on your locking hubs being the fuse, but it might be that your ujoints will be the fuse with chromo. either way 33s gotta be hammered pretty hard to bust another shaft.

[Dunenutt]

I have always had great luck with Superior axles.

Replace both axles, and let the hub be the fuse.

You should be able to upgrade from 27 spline to 30 also. ( I may be wrong, It's been a while) But you have to change the carrier.

[Dunenutt]

BTW, If you wind up the long shaft enough to break it, itwill usually take out the locker. The wound up long axle has a ton more stored energy than the short one.

[obijuan]

Dana 44s are 30 spline inners but a different pressure angle of the cut than the GM 30 spline ten bolt.
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