In addition to far better metallurgical properties than stock axles, we have always been impressed by Superior's more "engineered" approach to building axles. Dual heat treatment (through-hardening and induction hardening), rolled splines, and Superior's exclusive Torque-Equalizing Diameter Profiles (sizing the axles so that the long and short side have equal "give") add up to an axle with a design and execution that is, well, superior. We really wanted to rid ourselves of the unibearing plague, so we sourced a Warn hub conversion kit. If we were going to go through the trouble of adding the stronger bearing/hub conversion, it made sense to us to get the additional muscle of utilizing the much stouter 5-on-5-1/2-inch pattern. See how one thing leads to another and a quick, simple project gets a little more involved? With the new bolt pattern on the front, we now needed new Superior axleshafts for the Dana 44 in the rear also (these shafts come drilled with both bolt patterns for indecisive types).
The new bolt pattern, of course, created the need for new wheels. To solve the clearance problems we had previously encountered with 15-inch rims and a high-steer arm kit, we went with Mickey Thompson Classic II alloy wheels in a 16x8 size. The 16-inch rims also open the door to additional tire sizes and choices. These were paired with a set of the new Mickey Thompson Baja Radial ATZ tires in the LT285/75/16 size (roughly equivalent to a 33x11.50x16). The whole affair ended up being a truly "bolt-on" upgrade, even with our enhancements. Our original concept of an easy and cost-effective way of upgrading the XJ/MJ/TJ front housing with a Rubicon 44 housing was realized. The Comanche now sports a stronger and more capable front axle assembly. Reliability has been greatly increased, and the new tire-and-wheel combination gives every early indication of being a big winner.
 A little work with the welder...  A little work with the welder and a black semigloss rattle can, and the modified housing looks shelf-fresh again. |  Our traction aid of choice...  Our traction aid of choice for this project was the Eaton ELocker. Promising full lockup with the touch of a button and the installation ease of some simple wiring, we think this locker is an excellent choice for our application. |  Randy's Ring & Pinion was...  Randy's Ring & Pinion was our source for the Yukon Gear & Axle 4.10 ring-and-pinion and the installation kit needed to fill the housing. |
 Setting up gears is still...  Setting up gears is still not something we feel comfortable doing ourselves, so we let the experts at Desert Rat Truck Centers in Albuquerque apply their considerable expertise. With store locations across the Southwest and an extensive mail-order network, Desert Rat can supply a wide range of needs. |  The installation of the ELocker...  The installation of the ELocker is very straightforward. The only additional step over and above a "typical" gear installation is drilling a hole of the specified size in the housing. We chose to enlarge one of the existing holes on the Rubicon pumpkin. |  The location of the hole we...  The location of the hole we chose for the wires necessitated cutting the original connectors off to feed the wires through the supplied rubber plug we siliconed into place. We replaced the connectors with a quality GM-style sealed plug. |