Yukon Axle Dana 30

I'm putting chrome moly axles and outboard axle seals in a 97 TJ and I have a few questions
1) Is the ouside diameter of Yukon axles larger. (27 spline have not pulled apart to measure the differance)
2) Will the inner seal need replaced. (differant size)
3) The outboard tube seal is really tight on Yukon axle, is that normal.
I noticed that a number of you have installed the tube seal, any problems.
Thanks for any help.

1-No
2-No
3-Yes

Question: Why are you going with Yukon axles?

I wouldnt go Youkon.

I went over to longfields Super Axles and tested (read broke)ALL major up grades including stock and this is what we got


Stub shaft's were only what we tested.

PRODUCT ............................................ FT.LB. TORQUE.... Deg. of TWIST

TJ Rubi Longfield front(inner race)...........................................6, 800.......75
TJ Rubi Superior front (shaft failure).........................5,800........40
TJ Rubi US Alloy front(shaft failure)............................................5 ,000........40
TJ Rubi Yukon front(ear failure)............................................. .4,100........50
TJ Rubi stock front (ear failure)...............................2,500...... ..10
TJ Rubi stock front (ear failure)...............................2,000...... ..10

This was a test on Rubicon shafts but they have the exact same stub shaft as the D30. I know longfield is working on a D30 CV shaft but if you cant wait then I'd go with the Superior's. They have 2 types of axles, the discovery series made in India and the evolution series made in the USA. We tested the evolution series because thats what I had.

I see that supafly is a man of few words. The price on the Yukons were less money.Both were 4340 chrome moly. Is one just more expensive or better? I should of ask the question before I bought the shafts. If I look at the data supplied by mumblewood, My choice was not the best
I looked at the longfields and was concerned about moving the weak link to ring and pinion.
Cost was a concern for lonfields(and not answering the phone)
I put a set of Alloy X joints in.
What is superior doing that makes thier axles better than the rest?(material,hardening, etc.)
The yukon broke at 4100 ft. lbs. but 50 degs. the others only made it to 40 degs.(except longfield)
Why only test the stubs, are they the weak link?
Thanks for the info.

The U-joint is the weak link, but it almost always takes out the stub shaft. Your Yukon shafts are a huge improvement over stock, but for some reason the other companys product is proven stronger. Just run them, and if you do break, you could always upgrade the outer stub shafts. Its a super easy install, and here is a great site for helpful tips about TJ's: http://www.stu-offroad.com/siteindex.asp

This one in particular will walk you through the entire process with pics! http://www.stu-offroad.com/axle/d30/axle-1.htm

I like the Superior's because the machining is better quality and coming from a heat treater that does axle induction and heat treat(me) it is my belief that Superior has a better process. I also cant confirm this but I think they also use a better grade of material.

Thanks for the info and links. I'll put it together and see what else I can break.

The yukon axle diameter was .100 larger and splines were longer. Stock axle necked down at the end of the splines about .150(smallest area of the shaft). Yukon axle never smaller than the turned down area for the inner seal. Everything went together nicely, Thanks again for the help.