Dana 30 upgrades

A selectable locker like ARB, Yukon ZIP locker, OX locker to make sure you don't get stuck, and a set of 33" tires, and some 4.10 gears to help with power and crawling. Also, a spare set of hubs with the shafts already in them, and you're good to go. The Dana 30 is a pretty good little axle for 33" and down, and is even OK on 35's as long as you don't drive like a madman.
 
not sure what year you have, but if you have a vacuum disconnect with 2-piece axle shaft, they can be trobublesome...gut the disco unit and replace with a one piece shaft. Later model XJ's had a larger U-joint, you can upgrade shafts to gain this.
All XJs until late 1999 used a more desirable high pinion, in 2000-01, they went with low pinion.
 
Personally, I would go with a Spartan locker or a Lock-Right rather than an ARB, OX or other more expensive locker. I have the Spartan in the d30 in my 95 and I'm very happy with it. Can't tell it's there when in 2wd and half the price or less than an ARB, etc.

Get a spare set of the larger u-joint front shafts from a junkyard (pull the shafts & unit bearings together) and keep those for trail spares. If you don't have the larger u-joint shafts in your d30 now, get a set to run and keep your current shafts for a spare set. I've got a pile of stock d30 shafts for spares but I've never needed one yet (knock on wood).

What size tires are you planning on running? As mentioned, 33's are fine and 35's can work. Honestly d30's are so cheap, even if you bend the housing or something major just grab another one from the classifieds here or from a junkyard.
 
I have a 1988 2 door Cherokee Chief Dana 30 up front and a Dana 35 in the rear. Plan on taking the 35 out possibly a Dana 44 or an 8.8. I would like to run the 6.5in Clayton three link and 36in tires.
 
an 8.8 from a 96 to 01 exploder would be best. (disk brakes too) also any d30 from the newer xjs would work. its real easy to match a 373 setup like that. you can even go to 410 but those are harder to find. also as for brakes youd benefit from a dual diaphram brake booster and durrango master cylinder. then if you do a lift on it another cheap upgrade is the wj steering/brakes setup.

as for upgrades for the d30 itself. if money isnt an option then you can go with one of the nice eaten or arb lockers. if your more on a budget use an aussie or spartan locker. about the only other things i can think of are chromo shafts... which those can be expensive. i just run the oem shafts with 5-760 spicer ujoints in it.
 
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