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Old 10-07-2011, 10:09 PM   #1
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Exclamation Dana 44 Help!

Two weeks ago I pulled the fill plug on my D44 rear (98 TJ Sahara 112k miles) and found some pieces of what looked like a shim stuck to the magnet on it.

Tonight I pulled the cover to see what's going on. Below are pictures of what I found. It looks to me like a cracked Trac-Lok plate of some sort.

I would be very grateful if someone who is familiar with these things could please comment on what they think it is. Also, what is involved with pulling the diff apart and fixing it? And last, why would it have broken?

I really appreciate the help. I'm not afraid to roll up my sleeves and dive in, but I would like to first know how deep the water is!
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Old 10-08-2011, 02:54 PM   #2
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Just ordered a Trac-Lok rebuild kit from Randy's:
Dana 44 & 9.25 Chrysler TracLoc clutch kit. - DS 706352

I hope that the top piece in the picture of the rebuild kit is the part which is broken on my diff.

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Old 10-08-2011, 02:58 PM   #3
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Old 10-08-2011, 02:59 PM   #4
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Yep, that's part of the clutch pack. That same piece in my turdy 5 is cracked to, all though not that bad. I chose to leave it, it's not doing any harm other than the LSD not really working.

If I had a 44 however I would fix it or replace it with a better LSD or locker.
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Old 10-08-2011, 03:08 PM   #5
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I'm concerned that a section of that ring may break loose and mess up some teeth, otherwise I would just leave it alone. $80 for the kit (incl shipping) is worth it to me, and I'll get some experience pulling the diff apart.

I looked at replacing it with a Truetrac, but for me it's not really worth the $500 plus necessity of re-shimming the gears. If I could find a used one for half price, then maybe.
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Old 10-08-2011, 03:19 PM   #6
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Yep that would concern me to.

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