You don't have to run a dana 60 on the rear, you would just need two different wheels lug patterns, but I would recommend at least a 60 in the rear with 40's. You can get into a rear dana 60 for way less then $10,000. A full float prorock 60 with ARB and 35 spline shafts is around $6k

 

i seem to see a d60 ring and pinion blow every other week. At least thats been the pace lately...Could just be a bad run, but the stuff they are doing is extreme and there all on 40s plus v8s.

 

I guess I'm crazy but I'm running 37s on my stock 44 and haven't encountered any issues.

 

I have the PR44 on 37's and wheel a ton of huge technical rocks and haven't had an issue yet. I did run stock front shafts at first because I didn't have the extra coin, and broke one. Now I have chromoly and haven't had any issues. I don't doubt the PR44 could handle 40's. That being said wheeling technique is a huge factor in breakage. Knowing the right line, when to use the skinny peddle and when not to is a huge factor. I have also seen my fair share of 60 breaks, most of which were just poor wheeling, or just flat out hot dogging to put on a show.

 

It depends on how/what you wheel. This guys doesnt seem to need 40s by any means but wants them. Im sure the 44 will be fine for him. For some people no way it would work. As always theres a ton of variables. You can break anything. I personally just feel if you swapping an axle why not do it right. It will be more reliable and will come in handy if down the road you do more hardcore wheeling. Swapping axles is not something you would want to do twice.

 

I can't recall where I just read this (heck, may even be this thread), but the person noted that they never blew a stock axle shaft because they spot weld the u-joint caps. Apparently, that prevents them from coming apart and therefore, reduces/eliminates failures. Most of the stock shaft failures I see have been the joint.

 

that can help, but its also part of the reason some aftermarket u-joint use full circle clips. its always good practice to draw a line across the cap and shaft so you can see if theyve moved or anything with a quick visual inspection.

 

I would totally agree, the vast majority of broken shafts are from joint failure. That is what broke on mine.

 

Thanks for all the input everyone .

I guess the debate I have for myself is what is needed vs wanted. 40s obviously are not a need and only a want. Wheeling will most never if ever be extreme like some of you canyon crawlers out west. There are a few trails within an hour to 2 hours away ill see 1-2 times a year... Moderate routes taken only. Its a daily driven jeep that my wife drives as well. The most offroad it will see is my wifes family property in Louisiana, about 500 acres of beach sand, mud, swamp, creeks, and trails but no huge rocks of any sort.

I know full float 60's all around would be best, but spending such money on something that is best maybe 2 - 3 times ever just seems maybe over done.... But then it is 40s ... Back and forth I go..

 

You are going to hate 40's on the 2009 automatic, if you go that route you will be thinking of an engine swap and then you will definitly want the full float rear.