BonkersBaja
Forum Member
Why Dana 30? I've spent the last couple of years trying to figure out an ideal axle stub to pair with the Torque Master VA2 which fits right into the Subaru transmission differentials. There is no simple solution. One possibility, Torque Masters would need convinced to produce a new model (VA3?) with 28.5mm 25 splines for front diffs... which they seem opposed to. A second possibility is for front inner CV joint cups but with 26mm 25 splines to be sourced, probably from a Chinese manufacturer. That would undoubtedly require ordering a large quantity.
So, rather than searching for an axle stub to mate with an ideal locker, I began searching for an ideal axle stub and a locker to match it. Dana 30 is perfect. They're larger, stronger and the lockers often cheaper. Unlike the torq Master lockers with 26mm 25 spline, the Dana 30 is 29.3mm 27 spline. Machining the diff case for Dana 30 (doable, I've checked) and also the inner CV joint cups to accept Dana 30 axle stubs will produce lockers and inner CV cup shafts that exceed the original strength of the Subaru parts.
Any lunch box locker for Dana 30 could be used. Torq Masters because they have a great design. Powertrax No-Spin for it's syncronizer. Or a DL30-27 because they are very inexpensive (see Ebay item 316458899811). The Dana 30 shafts are a bit expensive outside of the USA due to shipping (see Ebay item 371451691121). That is the only iteration of Dana 30 shaft that will be suitable for the machining necessary.
I am curious about the WRX R180 27 spline. They are likely similar, but I think not a direct fit. Would somebody measure the spline diameter on a rear inner joint cup of R180 axle shaft for me? I think they're the same spline as the outer wheel bearing splines but I don't know for sure. Also the diameter of the polished and oil-grooved bearing surface would be useful.
I expect to build both a 5MT diff and one for a 4EAT during May, 2025. The build should also work in 6mt and CVT.
If anybody else wants to give it a try, I would be up for sharing guidance and ideas back and forth. I have many more details I can share.
So, rather than searching for an axle stub to mate with an ideal locker, I began searching for an ideal axle stub and a locker to match it. Dana 30 is perfect. They're larger, stronger and the lockers often cheaper. Unlike the torq Master lockers with 26mm 25 spline, the Dana 30 is 29.3mm 27 spline. Machining the diff case for Dana 30 (doable, I've checked) and also the inner CV joint cups to accept Dana 30 axle stubs will produce lockers and inner CV cup shafts that exceed the original strength of the Subaru parts.
Any lunch box locker for Dana 30 could be used. Torq Masters because they have a great design. Powertrax No-Spin for it's syncronizer. Or a DL30-27 because they are very inexpensive (see Ebay item 316458899811). The Dana 30 shafts are a bit expensive outside of the USA due to shipping (see Ebay item 371451691121). That is the only iteration of Dana 30 shaft that will be suitable for the machining necessary.
I am curious about the WRX R180 27 spline. They are likely similar, but I think not a direct fit. Would somebody measure the spline diameter on a rear inner joint cup of R180 axle shaft for me? I think they're the same spline as the outer wheel bearing splines but I don't know for sure. Also the diameter of the polished and oil-grooved bearing surface would be useful.
I expect to build both a 5MT diff and one for a 4EAT during May, 2025. The build should also work in 6mt and CVT.
If anybody else wants to give it a try, I would be up for sharing guidance and ideas back and forth. I have many more details I can share.