Before tearing into the axle, place the vehicle on level ground and off the trail. When using a Hi-Lift jack in sand and dirt, we always recommend using the off-road base since it provides more stability. A floor jack or scissors jack are another option if available.Before tearing into the axle, place the vehicle on level ground and off the trail. When us Trail repairs such as axleshaft swaps are simple and can be handled by anyone that can turn a wrench. However, a major thing to remember while making easy repairs in the wild is safety. Don't be careless. Our staff couldn't tell you how many times we've changed out a busted axleshaft on the trail-perhaps more times than we would like to remember. Since these repairs can take place in bad weather and rough terrain, they can be very dangerous, but easy safety procedures can prevent injury and perhaps save a life. Here is a quick look at how to break down the very common Dana 30 front axle. Found under many different Jeeps, the Dana 30 is one of the most common lightweight front axles. For this story we will focus on the newer-style Dana 30, the one most commonly found in the '97-'06 Jeep Wrangler TJ. Ratchet-strap the axle up to a secure point on the frame or body of the vehicle. Doing this will stop the axle from drooping when you jack up the vehicle and will keep it from being precariously high on the jack.Ratchet-strap the axle up to a secure point on the frame or body of the vehicle. Doing thi Never trust any jack. Always place objects like tires and rocks under the lowest point on the vehicle as a safety catch. If the jack tilts and falls, the rig will be supported by the tires and rocks-a lifesaver! Also, plan your escape route from the vehicle just in case it does fall.Never trust any jack. Always place objects like tires and rocks under the lowest point on Replacing an axleshaft on an axle assembly with a unit bearing hub assembly is easy and can be done quickly with the right tools. Since the Dana 30 does not come with a selectable hub from the factory, all that is needed to free the axleshaft is a 36mm socket.Replacing an axleshaft on an axle assembly with a unit bearing hub assembly is easy and ca The brake caliper must be removed so the rotor can be taken off. The caliper is held on by two bolts, once the bolts are removed the caliper can be pried off and should be secured to the vehicle so the brake line isn't damaged.The brake caliper must be removed so the rotor can be taken off. The caliper is held on by With the caliper removed, the rotor should pull right off. If it's frozen on the axle assembly, lightly tap it with a hammer while being careful not to hit the part of the rotor that comes in contact with the brake pad.With the caliper removed, the rotor should pull right off. If it's frozen on the axle asse There are three bolts that need to be removed from the steering knuckle in order to take off the unit bearing hub. A 13mm 12-point socket is needed on a Dana 30.There are three bolts that need to be removed from the steering knuckle in order to take o With the unit bearing assembly off the steering knuckle, the axleshaft can be removed from the housing. Retrieving the inner broken part of the shaft can be tricky. Sometimes a pair of long needle-nose pliers or a heavy duty magnet will work. If the shaft exploded, the diff cover may need to be removed so the broken pieces don't get lodged in the differential.With the unit bearing assembly off the steering knuckle, the axleshaft can be removed from Once the broken shaft is removed, the new axleshaft can be slid in place. Insert the shaft slowly so its splines line up with the differential. Don't force the new shaft in.Once the broken shaft is removed, the new axleshaft can be slid in place. Insert the shaft Always be prepared. Bring the right tools for minor repairs and large sockets and wrenches for components like axle nuts. Also bring parts you would need to repair things like axleshafts, driveshafts, and U-joints. If this is the very first axleshaft repair, place the components that have been taken off in a row in the order you removed them. This makes reassembly much easier.Always be prepared. Bring the right tools for minor repairs and large sockets and wrenches SOURCES Superior Axle & Gear 9580 Commerce Center Drive Rancho Cucamonga CA 91730 888-845-0470 www.superioraxlegear.com Overkill Engineering Nuevo CA 888-225-0243 www.overkilleng.com By Kevin McNulty Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!