Need To Replace my M220 and considering Dana 60 & UD44 but have some concerns

[DangerMTBBronco]

Long story short my rear M220 4.70 has a bad leak replaced the seals etc but still leaking. I think it's due to the pumpkin potentially flexing or I have a porous weld. FYI I welded the tubes a few years ago without properly heating up... and have wheeled pretty hard over 1000s of miles. So my options are replace the M220 with a new stock one find someone to weld the tubes properly or spend 4x and go D60 with U44s for additional strength.

My concerns beyond unnecessary cost is weight addition of the D60 and the ability to replace a U44 on the trail because I'm not going to be carrying backups and nobody is going to have one on the trail either. Think 1000 miles down in Baja Sur or UBB-type events where people likely have a stock CV to help get you off the trail.


Context: I have a 2022 Squatch Badlands equipped with an Icon Stage 8 kit and 37-inch Nittos, I have no plans to switch to larger tires or a wider stance/overall width.

Appreciate the info. Thanks!

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[PWillette]

@SierraBronco can get you pointed in the right direction.

 

[Beach_Bum]

Hate to state the obvious - but that stinks. Leaking diff gear oil is wretched.

 

[SierraBronco]

Seems like you know what to expect. The rear D60 isn’t going to be difficult to find parts for. And you can get them made to fit the Bronco with no problem, either through Dana or custom shops.

The front is another story. It is indeed harder to get replacements from Dana on the 32 spline axles. We broke one of the axles and dana did replace it under warranty, but it took months. RCV can make axles that fit, but it’s also been said that sometimes their customer service is also a tad on the slower side. With that said as long as you do your part by keeping droop and throttle in check, the 32 spline axles should probably last quite some time.

 

[Oldhippie]

I love the idea of a 60 rear, but if ya haven’t broke what ya got (I don’t hear about many folks breaking front or rear axles/diffs) it is just overkill. Fix/replace your rear and wheel it!

 

[SierraBronco]

I love the idea of a 60 rear, but if ya haven’t broke what ya got (I don’t hear about many folks breaking front or rear axles/diffs) it is just overkill. Fix/replace your rear and wheel it!

…a lot of people have broken their fronts and rears…like a lot a lot…

 

[Oldhippie]

…a lot of people have broken their fronts and rears…like a lot a lot…
[/QUOTE

ok…guess I live a sheltered life…

 

[DangerMTBBronco]

Seems like you know what to expect. The rear D60 isn’t going to be difficult to find parts for. And you can get them made to fit the Bronco with no problem, either through Dana or custom shops.

The front is another story. It is indeed harder to get replacements from Dana on the 32 spline axles. We broke one of the axles and dana did replace it under warranty, but it took months. RCV can make axles that fit, but it’s also been said that sometimes their customer service is also a tad on the slower side. With that said as long as you do your part by keeping droop and throttle in check, the 32 spline axles should probably last quite some time.

Always appreciate your feedback. And thanks again for the killer spotting on Plan B we had a blast.

I think I may stay with the M220 seeing as I can replace it 3 times before I hit the cost of the D60 snd U44 setup.

 

[Felix808]

I upgraded to a 32 spline FDU & would recommend it just to get rid of the aluminum tube. Not sure what tire size you plan on running but if you are 37's or lower, I would skip the D60. Too heavy & you'll lose diff clearance.
YMMV

 

[Felix808]

ok…guess I live a sheltered life…

Or have a sensible right foot

 

[SierraBronco]

Always appreciate your feedback. And thanks again for the killer spotting on Plan B we had a blast.

I think I may stay with the M220 seeing as I can replace it 3 times before I hit the cost of the D60 snd U44 setup.

Guess I haven’t looked at prices for awhile but our custom D60’s with OX lockers were $5280 a piece. Something like that.

 

[Oldhippie]

Or have a sensible right foot

Yeah, wheeling since the ‘60s, including over 50 rubicon trips, never broke an axle or diff…just lucky I guess…

 

[Brian_B]

Yeah, wheeling since the ‘60s, including over 50 rubicon trips, never broke an axle or diff…just lucky I guess…

Skilled.

Most wrecked axles or diffs I've heard of are from folks abusing lockers or using the accelerator pedal instead of a new line/more finesse.

If you find yourself saying "Hold my beer" or "Send it" often - you may be prone to broken axles.

 

[EvilJim1971]

…a lot of people have broken their fronts and rears…like a lot a lot…

I have been to the mall and coffee shop hundreds of times, occasionally when it isn't sunny.
Those people should be more careful.

 

[TruckCamper]

Replace the D44 with stock and don't weld it... less weight and less cost. I would consider the Barnes brackets as the factory ones are flimsy.

Weight adds strength but reduces capability. It's a balancing act

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