So, long time no update. I replaced the shot OEM fogs with Hella 700FF driving lights, and they are AWESOME. They make late-night lonely highway driving much safer when used in conjunction with the low beams.
Today I caught wind that there was a 5.9L Limited GC in the local boneyard, so after work I made a beeline for the place in the hopes that the rear end was still in it, even though I knew the engine/tranny/TC was already gone. Fortunately, it was still there! The (rather rare) 5.9s came with the stronger D44a and a Trac-Lok posi unit, a huge improvement over my open-diff D35. The D44a is a unique axle, it's called a D44 but has an aluminum center section with internals that are a hybrid of D44 and D60 stuff. The aluminum pumpkin is known to flex & eat carrier bearings if you
really beat on it and run big-ass tires, but if you truss it you've got an extremely stout axle, noticeably stronger than the iron-pumpkin Dana 44. So, a couple hours of wrenching, grunting, (and hacksawing a control arm in half) later, the diff was out and loaded into the Jeep. $118! Looks like it might need the pinion seal replaced, so I'll do that before I swap it in. A quick on-site test indicates the posi unit is in good shape. Hooray for traction! Next step is to either order the MVC truss/skid for $150 or make a clone myself. Decisions, decisions.
Fun fact: this diff is internally identical to the one used in the Dodge Viper.
Despite the aluminum chunk, that thing's heavy as shit to lift by yourself. :lol:
BONUS EDIT
Here's the axle specs compared to its brethren, you can see how it's a sort of hybrid.
Dana 35
Ring Gear Diameter = 7.562"
Pinion shaft Diameter = 1.376"
Ring Gear Bolt Count = 8
Pinion Spline = 26
Cover Bolt Count = 10
Axle Spline = 27
Dana 60
Ring Gear Diameter = 9.750"
Pinion shaft Diameter = 1.626"
Ring Gear Bolt Count = 12
Pinion Spline = 29
Cover Bolt Count = 10
Axle Spline = 30
Dana 44A
Ring Gear Diameter = 8.5"
Pinion Shaft Diameter = 1.625"
Ring Gear Bolt Count = 10
Pinion Spline = 29
Cover Bolt Count = 10
Axle Spline = 30
Dana 44 Iron
Ring Gear Diameter=8.500"
Pinion shaft Diameter=1.376"
Ring Gear Bolt Count=10
Pinion Spline=26
Cover Bolt Count=10
Axle Spline = 30
D44a vs D35 ring & pinion: