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Evan, I'll raise my hand. Since building my 2000 rig back in 2008, I've broken two D30 ring and pinions. The first was my fault, as I was playing in the dunes in 2010 and accidentally hit reverse while moving forward at 20mph. The second time I have no clue what caused it, I just noticed a...

Summit Machine Medium joint will work for the frame end of the track bar, don't rule out a high quality FK heim (Julene from Summit can provide these as well) at the axle end of the trackbar. I've run this setup for almost 2 decades, using the same Summit joint, replacing the heim once in 140k...

Jealous of the large garage and 2 post lift, glad that you can make this happen!

Thanks Fletch. My rig is sitting at just over 5.5" of lift. Depending on the tire mfgr., a 285/75/16 is going to measure out in the 32.5" tall and 11"-ish wide range, so trying to run these on a 3" lift with no trim is going to be a stretch.

This turned out pretty good!

I did this swap a few decades ago, replacing the BA-10 5 speed with an AW4. This was on a 89 Laredo, so none of my tech/wiring would be applicable. You'll need to verify trans output shaft/ t-case input shaft spline count. They might be the same for manual and auto on the late model XJs; the...

Some stroker progress. Dropped the crank and bearings into the block and checked for bearing/crank journal clearance. Bearing clearance spec is .0010 to .0025, all of mine are in the .0017-.0020 range. Bearing contact surfaces coated with Red Line Racing Assembly Lube before torquing to...

Check with ARB to verify that a JK D30 part number and an XJ D30 part number are the same. What size tires do you plan on running? I've never regretted stepping to 30 spline chro-moly shafts when my D30 ARB was installed.

Ive been running the 4.5" PSC pulley for about 9 yrs. Works great to give a much needed pressure bump at crawl speed.

You're clearly using the rig in extreme conditions, so upgrading to a higher quality speaker that can handle the elements will be beneficial to both performance and longevity. Might even want to look at marine rated speakers or SxS speakers, as they are waterproof-ish and designed to operate in...

When I installed MTX 2-way component speakers in the doors of my 2000 XJ, I added door baffles behind the speakers to minimize water and dust exposure inside the door. They've been in place for over 12 years and still sound great!

Prothane 6 Ring Coil Insert for use as a progressive bumpstop...

When you installed the inner sleeve, did you weld the sleeve to the axle tube......and the inner C? If so, this makes the C rotation project more complex.

I've rotated Inner C's with the diff still on the rig and several more with the diff on the stand. Off the rig makes it easier, but it's not a requirement to do the job.

I just realized that this tech landed on another thread and not on my build thread. I performed this mod back in 2010 and it's still getting the job done.

I rotated the inner C's on my HP D30 back in 2008 https://www.naxja.org/forum/showthread.php?t=913774&page=10 and since then, I have performed this mod on several XJ and JK front axle housings, with great success. Artec makes some great gussets, trusses and reinforcement bracketry to beef up...

Google Prothane Coil Spring Inserts

Guessing that you don't have 6" of lift then. I just measured the clearance from my TnT D30 truss to the oil pan and it's 7" of clearance, and my rig is sitting at just over 5.5" of lift. You can tune your bumps to provide clearance and minimize uptravel. I run Prothane coil inserts...

Is this the truss that you plan on installing? I've installed several Artec trusses on D30 axles for folks running 5-6" of lift on their XJ's, which is similar in design to the Barnes truss and pan to truss clearance has never been an issue.

WJ front brakes and steering. Major improvement for both on and offroad drivability. Montana Fab AW4 transmission shift controller. I use this every time I'm offroad and occasionally when in stop and go traffic to hold the trans in 1st or 2nd gear to reduce the need for constant braking.