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Old 01-02-2014, 12:23 PM   #1
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Dana 44 swap

I am going to swap a dana 44 from a 2005 tj with disk brakes. What will i need to do to make thise swap? I have approx 3-4 inches of suspension lift so will my stock driveshaft from my dana 35 work? Thanks!

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Old 01-02-2014, 12:30 PM   #2
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Not sure on driveshaft is 44 from a rubicon or non rubicon

Brakes should work with your master but do need brake lines with flex ends as calipers move

Also good to have e brake cables from disc setup

Should bolt right in

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Old 01-02-2014, 12:31 PM   #3
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You will need new ebrake cables and maybe a shorter driveshaft. Some are fine, some aren't. The dana 44 is about 1" longer at the yoke than the Dana 35. I have a 3.5" lift with DC rear driveshaft and everything was fine. Most people with some sort of lift over 2" or so are fine. Worst case just have a driveshaft shop make it a little shorter.

If its from a Rubicon you will need a 1330 to 1310 adapter ujoint.
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Old 01-02-2014, 01:32 PM   #4
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When I did my swap I had to get a different driveshaft because mine was to long. I was able to use all the stock brake stuff but my 44 had drum brakes. Also if it matters its a 98 with the 4.0 32rh auto and I had 4"of suspension lift
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Old 01-02-2014, 04:06 PM   #5
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The axle is from an lj. And also if i were to regear the axle to 4.11 gears would i need to buy a new carrier? It has 3.73 gearing right now with a lsd.
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Old 01-02-2014, 04:15 PM   #6
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No you don't need a new carrier. When I bought my D44 I bought his DS as well. what size tires? what transmission? I'm going to 35's and re-gearing to 4.88's. That is what multiple 4x4 shops have recommended.
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Old 01-02-2014, 04:16 PM   #7
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The axle is from an lj. And also if i were to regear the axle to 4.11 gears would i need to buy a new carrier? It has 3.73 gearing right now with a lsd.
U can get thick cut gears to go to 4.11 on a 3.73 carrier in the rear 44 and as for the front u are good cause the gear break on a d30 is 3.73 and up
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Old 01-02-2014, 04:19 PM   #8
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No you don't need a new carrier. When I bought my D44 I bought his DS as well. what size tires? what transmission? I'm going to 35's and re-gearing to 4.88's. That is what multiple 4x4 shops have recommended.
Using the other guys ds works if he has the same tranny as u otherwise they would still b different
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Old 01-02-2014, 04:33 PM   #9
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Can i get a link for thick cut gears? Thanks!
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Old 01-02-2014, 05:19 PM   #10
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Can i get a link for thick cut gears? Thanks!
Just when u call and order them tell whoever u order from u need thick cut gears and they will know what u mean.
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Old 01-03-2014, 12:35 PM   #11
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How slow will a 4 banger on 33s with 3.73 gearing be? Right now it has 4.10s but the axles im getting have 3.73 and i dont have the money to regear them yet
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Old 01-03-2014, 12:41 PM   #12
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How slow will a 4 banger on 33s with 3.73 gearing be? Right now it has 4.10s but the axles im getting have 3.73 and i dont have the money to regear them yet
That's probably going to be fairly noticeable difference
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Old 01-03-2014, 12:54 PM   #13
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I had 33s on 4.10 and it was a dog. I can't imagine what it would be with lower gearing. Just save up and do it soon
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Old 01-03-2014, 04:59 PM   #14
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Buy the rears, clean em up, and let em sit until you can afford to do the gears. It's much easier to do em on jackstands than in the dirt under the jeep. Once ya get the gears done, then slap em under.
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Old 01-03-2014, 05:10 PM   #15
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Buy the rears, clean em up, and let em sit until you can afford to do the gears. It's much easier to do em on jackstands than in the dirt under the jeep. Once ya get the gears done, then slap em under.
This is what I did
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Old 01-03-2014, 11:49 PM   #16
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For taking out the emergency drum brake cables from my dana 35 do i have to remove the center console to to remove the cables or is there and easier way? Thanks
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Old 01-04-2014, 12:42 AM   #17
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For taking out the emergency drum brake cables from my dana 35 do i have to remove the center console to to remove the cables or is there and easier way? Thanks
Just unbolt the cable from the adjuster under the tub. Theres a nut you can screw off to slip the cable ends out and remove them.
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Old 01-04-2014, 10:17 AM   #18
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Cool. Also if i get thick cut gears for the dana 44 can i put 4.88 gears in the stock carrier it came with?
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Old 01-04-2014, 11:05 AM   #19
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So something like this: http://www.4wheelparts.com/Drivetrai...FWMV7Aod4mkApw would fit in my stock carrier that is only supposed to go up to 3.73 gears? Thanks
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Old 01-04-2014, 11:16 AM   #20
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You're not doing the re-gear yourself are you? That's the ring & pinion which doesn't go inside the carrier. These gears go inside the carrier Dana 44 Spider Gear Kit.

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Old 01-04-2014, 11:20 AM   #21
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I just meant the gears that go in the axle i want 4.88 gears not spider gears the axle already has a lsd.
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Old 01-04-2014, 11:42 AM   #22
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If you are planning on paying a shop to install new 4.88 gears, do NOT buy the gears & other related parts on your own hoping to save a few bucks. Doing so will cause the biggest warranty headache imaginable should something go wrong during or after the installation. The installer will only warranty their labor, the dealer you bought the parts from will blame the installer for any problem... and 99.999% of the time, it is the installer that causes the problem.

And bad R&P installations happen do even with experienced installers, it happened to me 6 weeks after the installation was completed. Fortunately the installer had provided all the parts so they took care of it no questions asked.

You will need a new carrier for the Dana 44 to go to 4.88 unless you go with a thick cut ring gear. Personally I'd install a new carrier, they can be found for $60-80.
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Old 01-04-2014, 11:45 AM   #23
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Thanks Jerry, and are there any disadvantages with having a thick cut ring gear? I wanted to keep my carrier since it has a lsd in it.
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Old 01-04-2014, 12:07 PM   #24
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There are no real disadvantages to a thick-cut ring gear. But I really doubt your LSD is still functional since it is clutch based. The Tracloc LSD's clutch pack seldom lasts more than maybe 50k miles before it wears out.

The only LSD I would ever recommend is the Detroit Truetrac which is gear based, not clutch based. For that reason, the Truetrac doesn't really wear out... generally speaking of course.
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Old 01-04-2014, 12:33 PM   #25
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Do you think my stock driveshaft will work with the dana 44? I have an ax5 man tranny and about 3 inches of suspension lift in the rear
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Old 01-04-2014, 12:40 PM   #26
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I'd think your stock driveshaft will work fine since you have a 3" lift. Think back to the old right-triangle math... A2 + B2 = C2.

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