Revolution Gear & Axle 87-06 Wrangler TJ Dana 44 Chromoly Drum Brakes Discovery Series Rear...

If you broke or bent a rear shaft in a Wrangler with a Dana 44 out back, or you are building a TJ or YJ for bigger tires and want shafts that will not twist, this is the Revolution Gear and Axle Discovery Series rear axle kit, part number DC-D44-TJ-2. It is the drum-brake version for 1987-2006 Jeep Wrangler Dana 44 rear axles. The pair of shafts is made from 4140 chromoly steel and ships with the bearings, seals and retainers already pressed on, plus ten wheel studs packed loose.

What an axle shaft kit does in a Dana 44 rear

The Dana 44 is the 8.5-inch ring gear axle Jeep fitted to every 2003-2006 TJ Rubicon and offered as the rear axle option on Sport and Sahara TJs, and to a limited number of YJs; most YJs and many TJs left the factory with a Dana 35 instead. The axle shafts carry all of the rear torque from the differential side gears out to the wheel flange, and they also carry the vehicle weight on the outer bearing. Stock shafts are the weak link once tires get taller, lockers go in, or the Jeep sees rock crawling. Chromoly shafts in 4140 steel are tougher and more resistant to twisting at the splines than the factory parts, and the dual-drilled flange accepts both the 5x4.5 Jeep pattern and the 5x5.5 pattern.

Symptoms that call for new rear shafts

• A loud bang under power followed by no drive to one rear wheel (broken shaft or stripped splines)
• A rear wheel that wobbles, or a brake drum that will not seat flat on the flange (bent shaft)
• Gear oil on the inside of the drum, soaked brake shoes or a grinding rear wheel bearing
• A clicking or clunk that follows wheel speed after an off-road hit
• Planning a locker, gear change or larger tires and wanting shafts to match

How to confirm before you buy

First confirm you actually have a Dana 44 and not a Dana 35: check the axle tag on the cover bolts or the build sheet, because the two need completely different shafts. Then look at the rear wheel with the wheel off. A drum means this kit; a caliper and rotor means you need the disc brake version of this kit. Jack up one side, rock the wheel top to bottom for bearing play, and spin it to look for flange runout. If a shaft broke, pull the cover and check the side gears and carrier, since a broken shaft often takes the spider gears with it.

Fitment

Revolution lists this kit for 1987-2006 Jeep Wrangler with a Dana 44 rear axle and drum brakes, which takes in the YJ (1987-1995), the TJ (1997-2006) and the long-wheelbase TJ Unlimited (2004-2006) when they carry a Dana 44. Retail listings show the drum kit as the 30-spline shaft; a separate 33-spline kit exists for aftermarket carriers and lockers, so match your carrier's spline count before ordering. Several Jeep axles were also swapped between models over the years, so if your axle came out of another vehicle, measure your old shafts and count the splines first, or send us your year, VIN and axle tag and we will check it.

Install notes

• The bearings, seals and retainers come pressed on, so no press is needed. Install the ten wheel studs yourself with red thread locker and torque them to 90 ft-lb, per Revolution.
• Drain and clean the diff, inspect the side gears and carrier, and replace a worn carrier rather than putting new shafts into damaged splines. A 30-spline Dana 44 limited slip is a common upgrade at the same time.
• If you are re-gearing, set up the ring and pinion with a Dana 44 carrier installation kit before the shafts go in.
• Clean any gear oil off the brake shoes and drums, readjust the shoes and check the parking brake once the shafts are in.
• Refill with 75W-90 or 75W-140 gear oil, adding friction modifier if the axle has a clutch-type limited slip, and recheck the level after a short drive.

Revolution covers this kit with a 10-year limited warranty on manufacturing defects and axle breakage; bearings and seals are wear items and are not covered. Browse more axle and differential parts in our hard parts category.

Does this kit fit a Wrangler with a Dana 35 rear axle?

No. These shafts are only for a Dana 44 rear. Many YJs and Sport or Sahara TJs came with a Dana 35, which uses different shafts. Check the axle tag before ordering.

How do I know if I need the drum or disc brake version?

Pull a rear wheel. If you see a brake drum, this DC-D44-TJ-2 kit is the right one. If you see a caliper and rotor, order the disc brake version of the same kit instead.

What is included in the kit?

Two 4140 chromoly rear axle shafts with the bearings, seals and retainers pressed on and ready to install, plus ten wheel studs that ship loose so they are not damaged in transit.

What bolt pattern are the flanges?

The flanges are drilled for both 5x4.5 and 5x5.5, so you can run stock Jeep wheels or 5x5.5 wheels.

What gear oil should I use after installing the shafts?

Use 75W-90 or 75W-140 gear oil. If the axle has a clutch-type limited slip, add friction modifier unless the oil already contains it.

What warranty does the kit carry?

Revolution Gear and Axle backs it with a 10-year limited warranty covering manufacturing defects and axle breakage, bent axles and twisted splines. Bearings and seals are wear parts and are not covered.