Ep. 16 Dana 60 Swap: Is It Actually Worth It?

Howdy folks! Welcome back to the **Jeep Cherokee XJ Talk Show** with your host Tony Muckleroy from xjtalk.com! In this classic live call-in Q&A episode, we dive deep into real Jeep builds, troubleshooting, and community chatter with no scheduled guests — just great conversations from the XJ family. ### 🔥 Highlights: - **Scott (XJ4IV)** calls in with his ambitious **Dana 60 front axle swap** on his XJ — discussing the offset issues, switching to **Fox air shocks**, 37" tires, 5.13 gears, and more. A must-hear for anyone planning a big axle upgrade! - **Rene (Raney)** joins for the second night in a row — talking Rough Country lift kit experiences, winch problems (melted cables!), death wobble fixes, and why customer service matters. - Community questions answered: - Signs of **death wobble** and best fixes - Relocating the alternator while keeping A/C - Waterproofing distributors (dialectric grease, tent spray, VO5 hair spray?) - 2WD to 4WD conversion plans - How many different colors of XJs are in the XJTalk community? - Origin of the "Cherokee" name - Updates on new vendors, **Dirtbound Off-Road** NP242 hack-n-tap kit, Ironman 4x4, and the ongoing **Performance Distributors FireWire 4.0** ignition kit giveaway (vote for best question & promo!) A fun, laid-back episode full of practical XJ advice, trail stories, and Jeep Talk camaraderie. **Watch the full show and join the conversation at:** [xjtalk.com](https://xjtalk.com) 👉 **Like** if you're an XJ owner 👉 **Comment** below with your biggest XJ build challenge 👉 **Subscribe** and hit the bell for more Jeep Cherokee content! **Timestamps:** 00:00:00 Show Introduction and Call Info 00:01:31 Chat Participants and Call Setup 00:02:40 Sponsor Spotlight: Ironman 4x4 00:03:18 First Caller and Site Membership Changes 00:03:49 Dana 60 Axle Installation Challenges 00:05:01 Axle Fitment Issues and Cost Considerations 00:06:41 Preparing for Potempey Rocks Trip and Axle Modifications 00:07:54 Chevy Axle Swap Feasibility and Pricing 00:09:02 Air Shock Choice and Tire Acquisition 00:10:27 Tire Deal and Decision-Making Insight 00:11:07 Budget Strategies and Gear Procurement 00:12:18 Drivetrain Assembly Details and Tools 00:14:19 Custom Tool Fabrication and Wrap-up 00:14:44 Home Workshop and Neighbor Interaction 00:15:57 Rear Axle Options and Installation Plans 00:16:42 Call Management and Audience Participation 00:16:53 Encouraging More Callers 00:17:29 Welcoming Returning Member Scott 00:18:09 Vendor Highlights and Transfer Case Offer 00:18:32 Transfer Case Hack-and-Tap Cost Comparison 00:19:25 Transfer Case Yoke Installation Overview 00:19:50 Transfer Case Seal and Housing Details 00:20:30 Closing Caller Exchange 00:20:38 Live Call Appreciation and Timing 00:21:35 Electric Fan Upgrade for Cooling 00:23:22 Off-Road Wear Concerns and Sliders 00:23:58 Reeney Discusses NZ Earthquake Alerts 00:24:58 Earthquake and Tsunami Awareness 00:27:46 Tsunami Video Commentary 00:28:40 Chat Dynamics and Top Contributor Stats 00:32:15 Jeep Repairs, Gear Setup, and Member Interactions 00:37:33 Microphone Setup and Audio Feedback 00:37:47 Cheap Winch Experience and Inquiry 00:38:36 Rough Country Warranty and Customer Service 00:39:37 Winch Electrical Issues and Cable Failure 00:42:22 Muddy Festival Recovery and XJTalk Branding Ideas 00:48:22 Firewire Contest Q&A Session 00:51:59 Show Conclusion and Goodbyes 00:52:40 2WD to 4WD Conversion Planning 00:54:58 Lift Installation and Transmission Prep 00:55:29 Death Wobble Symptoms and Remedies 00:59:07 Alternator Relocation and Cooling Solutions 01:04:22 Distributor Waterproofing Techniques 01:07:26 Finalizing Death Wobble Segment 01:07:44 Origin of Jeep Cherokee Name 01:09:37 Jeep Naming History and Call Departures 01:10:48 Contest Updates and Social Media Promotion 01:13:34 Pillar Light Showcase 01:14:00 Final Closing Remarks #JeepCherokee #XJ #XJTalk #JeepBuild #OffRoad #Dana60 #DeathWobble #JeepLife *Classic episode from the xjtalk.com archives. Thanks for watching and supporting the Jeep community!* Visit our website: https://jeeptalkshow.com/ Watch/Listen on Spotify https://jeeptalkshow.com/spotify Join our Discord Server: https://jeeptalkshow.com/discord Subscribe to our newsletter: https://jeeptalkshow.com/newsletter Help Support the show via Patreon: https://jeeptalkshow.com/patreon