This page will have photos and details of the axles being put into the 5.9. HP30 front and Dana 44 rear. These axles are being built on a fairly tight "pick-a-part" budget.
(click on pictures to enlarge)
Here is a shot of the axles on the garage floor, you can see some of the trussing on the top of the D30.
The D44 will be fitted with a set of rear discs from a Ford Crown Victoria, these are the same style as a Ford Explorer/Grand Cherokee discs except the backing plate bolt pattern is the same as the Dana 44 (read direct bolt on!-no drilling) and the caliper piston and pads are larger.
I was going to use mopar retainers for a TJ Rubicon (part number 5083678AA need one for each side) these will need to be re-drilled instead I am just building a spacer to make up the difference between the drum and disc backing plates:
These mopar retainers make up for the caliper brackets extra thickness but have a different bolt pattern.
I haven't mounted the brake line brackets to the axle yet, I plan on doing mounting them similarly to how I mounted the set on the 8.25:
(see ZJ discs on an XJ for details on parking brake mounting for non-ZJ conversions and other misc)
This portion will need to be enlarged slightly for the bearing assembly to fit.
I just wanted to get some pics up, I will be adding info and more pictures as I really get into finishing these up, so check back regularly.