dana 41 upgrades

Long story short, I got a 41 rear and 25 front to replace my d44 and 27 front because I stripped the pinion gear on the rear and the front ring gear is missing a few teeth. Didn't really want these axles but were the only thing around here that I find that would fit without mods. I found out the 41 only has 10 splines and that the 19 spline shafts from my 44 will swap in. I have never tore into axle gears before so any advice you can give will be much appreciated. My 44 has a power lock and I am hoping it can be swapped over as well. I also heard you can swap the 27 axle shafts over to the 25 too, my 25 also has a powerlock and hope it will swap as well. Is this something I can do since I've never worked on axle gears before. I have good mechanical skills, but have just never been inside the diff before other than installing one piece axles in the AMC20. The 44 & 27 had 4.88 gears and the 41 & 25 have 5.38,s. thanks for any and all input. Oh, I know about the FF kit for the 41 but im not putting any money into these axles as they are temporary for now. Just hoping to swap axles shafts and powerlock for some added strength.

 

The 27 axles will fit in the 25. The Powerlock will not fit the 41. You can put 19 spline shafts in a 41 but must change the side gears. May have to change the thrust block, I can't remember for sure. I do know the 10 spline and 19 spline thrust blocks are different diameters. I could probably check Monday if you need.


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Personally I don't think the swapping effort is worthwhile if you consider these axles as temporary.

 

I have to agree.


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So you think they will be fine if im light footed on the gas for a year or so. I have a 350hp chevy 327 in my jeep. If the fronts will directly swap I will do that but may not mess with the side gear swaping on the 41 if you think it will last a while.. Thanks

 

I seen a typo in my post. My 27 has the power lock not the 25, will it swap over along with the shafts? On the 41 and the brake drums are behind the axle flange, can I put the brakes from my 44 on the 41 including the backing plate? That stinks that the powerlock wont swap from the 44 to the 41, really was hoping for that. Thanks for you help

 

The brakes will swap. No the Powerlock will not swap. The 41 wi hold up about the same as a 44 with 10 spline axles. If you're easy on it it will probably be fine if in good condition.


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Thanks Nick, your input really helps.