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Old 07-14-2013, 08:51 PM   #1
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Axle swap problem

Ok so I just swapped in a D44 into my 97 TJ and now the pinion angle is way off. The D44 came out of a stock 01 TJ. The pinion angle was fine with the D35 before I took it out. All I did was swap the D35 out for the D44. What is the Different in the stock TJ D44 versus the Stock D35 that it throws the pinion angle off so much that I need adjustable uppers to fix it. I'm just confused, There both stock TJ axles and the D44 I thought would bolt right up with no problems. I'm hoping someone will help me understand what the difference is or what I have wrong. Here is some pics.

This is what it looked like before the swap D35

After swap D44


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Old 07-14-2013, 09:00 PM   #2
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WTF is going on with those rear lower control arms? The ones pictured with the D44 installed..........

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Old 07-14-2013, 09:06 PM   #3
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there pro comp boxed control arms
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Old 07-14-2013, 09:12 PM   #4
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Did you replace the stock LCAs with the pro comp arms during the swap? If so, the pro comp arms are longer this rotating your pinion angle down.
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Old 07-14-2013, 09:24 PM   #5
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Did you replace the stock LCAs with the pro comp arms during the swap? If so, the pro comp arms are longer this rotating your pinion angle down.
I put them side by side before I installed them and they where the same length. I stuck the bolt in the stock arms and the bolt lined up with the pro comp ones. So how are they longer?
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Old 07-14-2013, 09:41 PM   #6
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My bad. Figured the pro comp arms would be longer.
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Old 07-14-2013, 09:43 PM   #7
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I don't know if it's enough to cause that much misalignment but I'm pretty sure the D44 yoke is an inch or so closer to the tcase than the D35. Either larger housing or longer pinion.
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Old 07-14-2013, 09:46 PM   #8
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My bad. Figured the pro comp arms would be longer.
its cool, trust me I thought of that to lol
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Old 07-14-2013, 09:48 PM   #9
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I don't know if it's enough to cause that much misalignment but I'm pretty sure the D44 yoke is an inch or so closer to the tcase than the D35. Either larger housing or longer pinion.
yea but it came out of another TJ that is set up just like mine.
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Old 07-14-2013, 09:57 PM   #10
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If I'm understanding correctly the donor TJ was factory with D44 while yours was D35. If that's correct, when you swapped in the D44 it shortened your drive shaft and caused a steeper angle.
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Old 07-14-2013, 09:57 PM   #11
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Did you reattach your rear sway bar and take it for a ride yet?
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Old 07-14-2013, 09:59 PM   #12
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If I'm understanding correctly the donor TJ was factory with D44 while yours was D35. If that's correct, when you swapped in the D44 it shortened your drive shaft and caused a steeper angle.
Looking at the exposed area of the shaft where the slip is Id say they look the same length to me.
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Old 07-14-2013, 10:01 PM   #13
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It does look that way but while researching to do the same swap I was sure I read that.
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Old 07-14-2013, 10:06 PM   #14
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If I'm understanding correctly the donor TJ was factory with D44 while yours was D35. If that's correct, when you swapped in the D44 it shortened your drive shaft and caused a steeper angle.
im not sure it doesn't look like enough of a difference to change the angle that much

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Did you reattach your rear sway bar and take it for a ride yet?
yes and I get drive line vibration under acceleration from about 1500 to just over 2500 rpm.
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Old 07-14-2013, 10:14 PM   #15
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Ok I found the thread I was thinking of. The posters TJ was an auto and the donor d44 was from a manual. The drive shaft was one inch to long. I apologize.
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Old 07-14-2013, 10:19 PM   #16
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Ok I found the thread I was thinking of. The posters TJ was an auto and the donor d44 was from a manual. The drive shaft was one inch to long. I apologize.
ahhh ok. yes both donor and mine are manuals. hopefully someone will know why im having this problem. Plus I have a SYE. I have upper adjustable ones on the way but im trying to figure out why I even need them at all.
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Old 07-14-2013, 10:31 PM   #17
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Looking very closely i see old springs on the floor near the old axle and new springs on the Jeep. Did you install a lift?
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Old 07-14-2013, 10:34 PM   #18
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it already had a lift I just swapped springs.
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Old 07-14-2013, 10:38 PM   #19
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Did you gain any height? Not trying to pester you just help work though the problem.
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Old 07-14-2013, 10:40 PM   #20
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Did you gain any height? Not trying to pester you just help work though the problem.
no your good. no its the same height 4in. just new springs with less miles on them.
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Old 07-15-2013, 07:51 AM   #21
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bump. hopefully someone can help
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Old 07-15-2013, 08:18 AM   #22
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If your running a 4" lift and a SYE then it's past time you had adjustable control arms, perhaps you should find out what the stock arm length is on a TJ equipped with a D-44, the Procomp arms may be the same as your old arms, but your old arms were holding in a D-35, not a 44.
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Old 07-15-2013, 05:38 PM   #23
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Bump. I am curious as to what is going on. Good luck
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Old 07-15-2013, 09:21 PM   #24
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If your running a 4" lift and a SYE then it's past time you had adjustable control arms, perhaps you should find out what the stock arm length is on a TJ equipped with a D-44, the Procomp arms may be the same as your old arms, but your old arms were holding in a D-35, not a 44.
its a stock D44 out of a TJ. My question is what is the difference in the D44 that it would do this? When you order a lift, you order it for a TJ. It doesn't ask if it has a D44 or D35 in it. So obviously there shouldn't be any difference in the two. Everything is the same in the suspension regardless of what rear-end is in it. Ive been running a 4in lift for 5 yrs with no adjustable uppers and at least 6 months with the lift and SYE with no problems. I pull the D35 out and swap in a D44 and this is what happens.
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Old 07-15-2013, 10:15 PM   #25
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You didn't happen to do anything to change the height of the transfer case did u? If not, maybe your old springs had sagged?
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Old 07-15-2013, 10:25 PM   #26
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Weird for sure. Should not be that big of a difference if swapping stock for stock.

Did you happen to compare the control arm brackets on both axles while they were sitting next to each other on the garage floor?

I know you said your D44 is all stock, but sometimes people weld different brackets on if they tear one off.

My control arm brackets were all aftermarket on my D44 donor axle. But I had adjustable arms so it didn't really matter.

Definitely curious to find out what it is. Good luck.
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Old 07-15-2013, 10:36 PM   #27
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I've talked to my local driveline shop before about this your drive shaft needs to be shortened about 1.5-2 inches the dana 44 is longer at the yoke and the reason a lift is able to be put on either a d35 or d44 jeep is because the stock driveshafts are different for each. Also when you buy a cv shaft that is pre-measured for a lift height it asks or tells you what axle it is for.
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Old 07-16-2013, 06:21 AM   #28
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I've talked to my local driveline shop before about this your drive shaft needs to be shortened about 1.5-2 inches the dana 44 is longer at the yoke and the reason a lift is able to be put on either a d35 or d44 jeep is because the stock driveshafts are different for each. Also when you buy a cv shaft that is pre-measured for a lift height it asks or tells you what axle it is for.
As I stated in my first post, I thought that was the case. Then I second guessed myself. Thanks for the confirmation.
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Old 07-16-2013, 06:31 AM   #29
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If your willing to start from zero and entertain some questions, it could be helpful but could also be annoying and frustrating.

How do you know what the axle came from? Did you take it off? Can you be sure it was stock? Can you post a pic of the diff cover?

Again, I don't mean to insult or annoy, but, just going from memory, that pumpkin doesn't strike me a resembling a d44.

Just trying to help, it's quite the mystery.
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Old 07-16-2013, 09:42 AM   #30
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Need a lot more pics......closeups of the brackets on the new axle, the pumpkin.......pics that allow you to see the orientation between the pumpkin and the brackets etc........

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