Revolution Gear & Axle Jeep TJ/YJ/XJ Dana 30 w/27 Spline Chromoly Discovery Series Front Axle Kit
A broken front shaft on a Wrangler or Cherokee usually happens at the worst moment: wheels cranked, locker engaged, tire hooked on a ledge. Revolution Gear and Axle DC-D30-TJ is a Discovery Series 4340 chromoly front axle kit for the Dana 30 under the Jeep Wrangler TJ, Wrangler YJ, and Cherokee XJ with 27-spline axles. It replaces both inner shafts and both outer stubs and comes with new joints, so you rebuild the whole front driveline in one go instead of chasing the next weak link.
The Dana 30 is a small front axle, and its 27-spline shafts are the fuse in the system. The inner shafts ride in the side gears of the carrier and run out to the knuckles, where a U-joint connects each one to an outer stub. The stub passes through the unit bearing and turns the wheel. Under a locker or a limited slip, one tire can take all of the torque, and at full steering lock the U-joint is working at a steep angle at the same time. That combination is why stock joints and stub shafts are the first things to break once a Jeep sees larger tires.
The kit includes two 4340 chromoly inner axles, two 4340 chromoly outer stub axles, two Dana Spicer 5-760X U-joints, and eight full-circle snap rings. Axle seals are not included.
With the front end in the air and the transfer case in neutral, rotate each front wheel. If one wheel turns but neither the driveshaft nor the other wheel moves, something between the side gear and that unit bearing is broken. Pull the unit bearing to inspect the joint and stub. Also check the carrier: chewed side gear splines or a cracked spider gear means the diff needs work too. Our Dana 30 front axle problems guide covers what fails and what a rebuild costs, and the Dana 30 vs Dana 44 comparison helps if you are weighing an axle swap instead.
Revolution lists this kit for Jeep Wrangler TJ, Wrangler YJ, and Cherokee XJ models with a Dana 30 front axle and 27-spline shafts. It does not fit a 2003-06 TJ Rubicon, which left the factory with a Dana 44 front, and it does not fit a Dana 30 that has been fitted with 30-spline shafts; Revolution sells that version separately. Some YJ and XJ axles use a vacuum center axle disconnect on the passenger side, so tell us if yours still has it and we will confirm compatibility before you order. Count your shaft splines and send year and VIN if you have any doubt. More Jeep axle parts are in our hard parts category.
| Brand | Revolution Gear & Axle |
| Part number | DC-D30-TJ |
| Fits | Revolution Gear & Axle Jeep TJ/YJ/XJ Dana 30 w/27 Spline Chromoly Discovery Series Front Axle Kit |
| Type | Axles |
| Condition | New |
| Ships | Same business day (in stock), from the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
No. The 2003-06 TJ Rubicon came with a Dana 44 front axle. This kit is for the Dana 30 front with 27-spline shafts.
Two Dana Spicer 5-760X U-joints are included along with eight full-circle snap rings, two chromoly inner shafts, and two chromoly outer stubs.
Factory Dana 30 shafts in the TJ, YJ, and XJ are 27 spline. If the axle has been upgraded with a 30-spline locker or shafts, count the splines on the inner shaft end before ordering.
No. Replace the inner tube seals during installation so gear oil stays in the housing and away from the new joints.
Inspect the unit bearings, ball joints, and carrier side gears. Worn unit bearings and leaking seals are common on high-mile TJ and XJ front ends.
