12. Here you can see a converted front axle installed in a TJ Unlimited. This particular axle is a Dana 30 out of a JK. Which leads us to another point. The JK-to-TJ Axle Conversion Kit can also be used to fit the JK Dana 30 under a TJ. The conversion is identical. This particular axle was used for a couple of reasons. First, the rig was being converted to a diesel powerplant and the engine management system requires input from the ABS sensors found in the JK axle. Second, the owner wanted to run an ARB Air Locker and the JK Rubicon Dana 44 cannot currently be fitted with any locker other than the factory electric unit. Burnsville owner Dan McKeag says this is due to the design of the carrier bearings.
13. A shorter drag link is required. This vehicle had a drag link that had been cut and sleeved (shown), but the kit now comes with a chrome-moly drag link as standard equipment. When it comes to track bars, a stock JK unit is standard and an adjustable aftermarket unit is optional.
 14. If the axle is being fitted...  14. If the axle is being fitted into a '97-'02 TJ, a longer JK pitman arm will be needed to get full lock-to-lock steering. This step isn't required on newer TJ's because they use a fast-ratio Mercedes steering box. |  15. Here you can see one of...  15. Here you can see one of the front sway bar mounts. Normally, they aren't fitted until the axle is installed due to the many different types of sway bar disconnects being used by customers. |  17. The spring perches are... 17. The spring perches are tack-welded into place on the axletubes first. |
 18. Next up are the upper...  18. Next up are the upper and lower control arm brackets. |  19. The track bar bracket...  19. The track bar bracket is the last item to be positioned. |  20. The actual welding on...  20. The actual welding on the rear axle goes a bit quicker than the front axle because there's less bracketry. |
 21. After all of the bracketry...  21. After all of the bracketry is welded on, the welds are smoothed, the axle is painted and then it's ready to be installed. |  22. Here you can see a JK... 22. Here you can see a JK Rubicon Dana 44 installed in a TJ. New driveshafts will have to be made, and Burnsville uses Tom Wood's Custom Drive Shafts. Since the JK Rubicon axles utilize electric lockers, making them function is as easy as feeding them 12-volt power and installing the switches. |  23. Because the JK axles are...  23. Because the JK axles are 5 inches wider than the TJ axles, the wheel/tire combination will protrude from the fenderwells, but as you can see, it's nothing major. This TJ is running stock JK wheels on stock-sized tires. The JK axles use a 5 on 5 bolt pattern, instead of the 5 on 4 bolt pattern of the TJ. |
 24. Here's another example...  24. Here's another example of a converted JK Rubicon Dana 44. This axle is in a YJ, and has coilovers, JK TeraFlex long-arms, a chrome-moly tie rod and drag link, and PSC hydraulic-assist steering. |  25. This '03 TJ Rubicon has...  25. This '03 TJ Rubicon has a JK Rubicon Dana 44; stock JK drag link, tie rod, and track bar; coilovers; Timbren bumpstops; and Rubicon Express long-arm control arms. | |
Bottom Line
So you're probably wondering what kind of costs are involved for this swap. Well, there are several options. If you're a do-it-yourselfer, you can walk out with a front axle kit for $845. You'll need to add about $50 for the JK pitman arm if your rig is a '97-'02. The bracket kit to fit the rear JK Dana 44 under your TJ is $300. You'll also need to plan to spend approximately $450 each for new driveshafts. If you want to bring a pair of JK axles to the boys at Burnsville, have them remove all of the factory bracketry, and install all of the new bracketry so you can install the axles and steering yourself, plan on approximately $1,495 for the front axle and approximately $650 for the rear axle. Once again, you'll need those driveshaft modifications. If you just want to drop your TJ at Burnsville and have them do all the work so you can drive out with a pair of fully functioning JK Rubicon Dana 44's under your TJ, it'll cost you approximately $4,095 for the front axle and approximately $3,325 for the rear axle. No matter which option you choose, you'll need to plan to procure wheels with the 5 on 5 lug pattern.