My D30 is the original axle that came under our 1998 TJ, so it is a low pinion, not a high pinion. You would not want to go back to a low pinion D30.
I looked at 3 options for changing out my front axle:
1) HP 30 out of an XJ w/added axle tube liners (stronger R&P, but limited to 4.88 gears) also direct bolt-in and least expensive and probably easiest and quickest.
2) HP 44 out of an old Scout (lots of axle mods required including all the TJ bracketry)
3) Dynatrac HP 44 w/RCV axles(strongest, should have been quick, can get 5.13 gears) most expensive
I went with the Dynatrac 44, but I probably should have just done the XJ HP30 swap.
When I looked for XJ D30’s at semi-local pick and pull salvage yards, the axles went not expensive. They were in the $150 to $225 range. But, as you said, lots of labor swaping all your stuff over.
Setting the caster is easy. Just get a digital level; something like below for $40. Set the axle up up on jack stands level. You can check the caster off the top the top ball joint. You can easily get within .1 to .2 degrees and that is good enough for a jeep. There is no camber adjustment and you can measure and set toe-in with a tape measure.
With that 5x5.5 conversion, couldn’t you just get the tube close to right, weld it in, pull the drive shaft, both axle shafts (or just unlock the hubs) and just run around in 2wd until you get back home?
What year is your jeep?
Brad
