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Old 09-06-2012, 01:01 PM   #1
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Question Tj dana 44 rebuild help

I have bought a Dana 44 off another Tj. I want to replace the Dana 35 I have in my Tj. The Dana 44 need some rebuilding, bearing, gears, brakes (add more to this if you can help me) etc. Right now its completely disassembled except the carrier which is still inside the housing. Other than that axle shafts are out, all brake parts are off the housing. It's stripped clean except that carrier and I haven't touched the linking either. What I'm asking is where do I begin. I have a new carrier, master install kit, bearings, and 4.88 gear and pinion, and alloy axle shafts (I have 4.88s in the front already) ready to go (add whatever to the list to help me out). No I am not putting a locker in. I have the parts, where do I begin to put it back together? I'm trying to keep this thread strictly to rebuilding Dana 44 axles and replacing the Dana 35. Step by step would help. Most work will be done in garage, probably have to see someone about pressing bearing in... All help is welcome and thank you!!!!

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Old 09-06-2012, 01:47 PM   #2
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Originally Posted by guzzywrangler View Post
I have bought a Dana 44 off another Tj. I want to replace the Dana 35 I have in my Tj. The Dana 44 need some rebuilding, bearing, gears, brakes (add more to this if you can help me) etc. Right now its completely disassembled except the carrier which is still inside the housing. Other than that axle shafts are out, all brake parts are off the housing. It's stripped clean except that carrier and I haven't touched the linking either. What I'm asking is where do I begin. I have a new carrier, master install kit, bearings, and 4.88 gear and pinion, and alloy axle shafts (I have 4.88s in the front already) ready to go (add whatever to the list to help me out). No I am not putting a locker in. I have the parts, where do I begin to put it back together? I'm trying to keep this thread strictly to rebuilding Dana 44 axles and replacing the Dana 35. Step by step would help. Most work will be done in garage, probably have to see someone about pressing bearing in... All help is welcome and thank you!!!!
Pinion* not linking

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Old 09-06-2012, 02:00 PM   #3
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The axle itself will bolt right in place of the dana 35. You might need to make some adjustments to the driveshaft. As for the 4.88's I am thinking you may need a new carrier for them, depend what gears the dana 44 had in them. Thus, I would replace all the bearings get a master install kit for the new gears, gears and have a shop do the install of the gears, unless you have done that type of work before. that's the short version.
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Old 09-06-2012, 03:20 PM   #4
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Im not trying to be sarcastic.... seriously.....

If you need to know how to rebuild your D44 with the correct carrier for the gears, replacing bearings, adjusting pinion depth, setting preload on the pinion, backlash and correct gear pattern for drive and coast side of your ring gear and shims for correction..... take it to a shop and have them do it.

In all seriousness... is it worth the money you spent on the all the parts you bought to have it completely redone in say 500-1000 miles and pay out again if YOU don't get it right? I highly doubt it.

I'm not knocking your abilities since I don't know what they are.... just by you asking the questions on the rebuild make me believe you have never done this. I have done 3, but not alone and don't feel comfortable enough yet to do one by myself without my friend who does it for a living.
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Old 09-07-2012, 01:56 PM   #5
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I appreciate both inputs.. I understand and realize it would be a hefty forum to list every step. The point is to teach myself. I know people have done it before at home and thats what I would like to learn. I do have a friend whose been doing this for years and most likely will do the set up with him. I guess as I go and have questions, post them!
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Old 09-07-2012, 02:46 PM   #6
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As long as you have someone that knows how... AND... has been doing so for quite some time, you should be ok..... Have your friend be there every step of the way and ask him questions on procedures and why he does it.... have him explain as he take you through the entire process.... you can't beat the hands-on experience.

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