Dana 44 Powr-lok Options

Hey all - first post here. I have a '69 CJ-5, Dauntless, T-14, D18, OD w/ stock 4.88 and a Powr-Lok in the rear. The Powr-Lok decided that all of the bolts holding it together would be better in two pieces rather than one. While bolts are easily replaced, the side gears that they took out are not. So, I'm looking for options. Here are my criteria:

• I'd like to keep it relatively stock while retaining the LS functionality. I.E., I don't want to swap axle housings or upgrade to discs. I want it to still 'look' like a stock axle.
• I'd also like to ditch the 2-piece axles.
• I don't want to spend a fortune.

I also have a 30 spline Dana 44 posi (3.53) on the shelf out of the front end of a 90's Bronco.

Here's what I'm thinking:

• Install the posi with a ring gear spacer
• Have custom 1-piece axles made as I can't find anyone who makes 30 spline axles for this application OTS.

What I don't know is how the wheel bearing and seal situation will work with 1-piece axles. Will there be an issue with setting bearing preload and/or assembly sequence? I have most all of the equipment necessary to make modifications to the housing and part of me wants to replace the housing ends with Ford 9" small bearings to get something more 'modern' that is easier to setup and maintain.


I'm sure that this has been covered before but I haven't been able to find this specific scenario. What would you do?

 

A D44 axle housing designed for use with tapered shafts simply will not work with one piece/flanged axle shafts.
However you can use a tapered D44 axle housing with full floating axle shafts.

 

A D44 axle housing designed for use with tapered shafts simply will not work with one piece/flanged axle shafts.
However you can use a tapered D44 axle housing with full floating axle shafts.

Thanks oldtime. That was my suspicion. What's the limiting factor? I'm assuming it's the fact the flange must be removed to access the bearing retainer? Could this not be overcome by installing ford 9" housing ends and redrilling the backing plates to match?

 

I would see if someone or a reputable company would trade the 3.53 case for a 4.88 case.
Then go full float the traditional way with drive flanges or lockout hubs on the rear.

You can get 1pc shafts but that requires custom spindles from a member (jpet) on the 2a page.

 

I would definitely do the full floater, but a 30 spline won't fit through the D30 spindle you would use. I think there has been some discussion here about 30 spline floaters, I don't remember where that ended up. My opinion, if you are not doing big tires in the rocks, a 19 spline (I assume your PL is 19 spline now), is plenty strong, then the floater works with common parts (D30 spindles and hubs, bearings), and Moser will make you some nice 1-piece 19 spline floater axles that will slide right in, be plenty strong, and look awesome too. But to do that, you either need to repair or replace the power lock, or install some other LS or locker of your choice.

 

Bore the d30 disk spindles to 1.81 ID. Have moser cut d44 30 spline 75 or so blazer long side down to size or buy custom shafts…

you can buy new Yukon power locks.
https://www.npdlink.com/product/locking-differential-assy-yukon-power-lock-positraction/201722

 

Correct; the taper axle housing “flange” does not work with one piece axles.
Also the tube diameter is 1/4” smaller diameter than an axle with one piece shafts.
The D44 carrier section presents no issues should you decide on larger diameter 30 splined shafts.
“IF” you can find; simply buy a set of Powr Lok 30 spline side gears to repair your differential.
That said, note those gears are especially hard to find.

 

I concur with this. The 19 spline full floater did just fine in my 3B for 4+ decades behind a pair of small block Chevy's (350 and 381). Zero problems with those, the caveat being they never saw anything bigger than 33" tires and it's a reasonably light Willys. Those shafts were run with both a Powr-Lok and Detroit Locker. If one wants to go with a 30 spline full float and still have some meat left in the spindle, I think Brennan Metcalf (Brennan's Garage) may be making the spindles that Jeff Petrowich designed now. Those will pass a 30 spline axle and still utilize the D30 hubs.

 

Richard at R&P is having spindles made that allow a 30 spline shaft to fit through and has a deeper step on the back with an o-ring to seal inside the housing. Mimics the Warn spindles.
I have a set of 30 spline gears for a 44 Powerlock if interested. I just haven’t posted them for sale yet.
I don’t like using a ring gear spacer. Another point of failure, and I’ve seen a lot of failures when they were used.
What limited slip do you have from the front? Not all are created equal and some are vehicle end specific.

 

I should have said that this is mainly a street vehicle with some light off-roading. I have it on Deestone 503's that are about 32" tall so nothing crazy.

So here's the question - does anyone make a 19 spline posi OR 30 spline 2-piece axles? Or am I stuck with going with a full floater?

 

There is a plethora of 19 spline posi's and lockers made for your differential. The most cost effective and simplest option is to r&r with one of them. Given your tire size and use I wouldn't be concerned with the tapered shafts.

 

They are available: https://www.theedgeautomotive.com/p...-complete-posi-uses-25590-nitro-gear-and-axle

I've heard originals from back in the 60s are better quality than the currently made ones. My '69 has 19 spline tapered axles with a factory Power Loc. Posting a "Want To Buy" add in the classifieds might find you one from another member.

 

You might trying to call Tom at Foothill Offroad at 530-889-2021.
This is old information, but I did receive propritary drawings and information from another member here who stated that these folks had axles made, or were going to make them for this conversion several years ago.
This was replacing two piece tapered shafts with a one piece flanged axle into the taperd axle housing.
Good luck.

 

That says that it's for 3.73 and down which won't work. I can't find a listing for 3.92 and up there or either on the manufacturers website.

The only posi for 19 spline 3.92 and up that I can find is this:

https://eastcoastgearsupply.com/i-23795192-auburn-dana-44-posi-3-92-up-19-spline.html

Yes, there are a ton of limited slip options for 30 spline axles but no 2-piece 30 spline axles that I can find. So then you have to go full floater? I feel like I'm missing something here.

There are lockers available, of course, but most would require buying a new open carrier. And I'm not sure I want a locker in a primarily street driven vehicle.

 

There are no off the shelf 30 spline axles to fit a tapered housing unless Foothill is making them. Dutchman Motorsports in Idaho “might” build you some if you supply all the dimensions. Jeep changed the design of the housing ends when the 30 spline axles came out in ‘70 1/2 for a couple reasons. I’m unaware of anyone making 19 spline one piece conversion axles. Basically you are locked into 19 spline tapered axles or a full float conversion.
Is your existing Powerlock case still usable? Maybe you can find the side gears and such that you need to fix it. For your professed use tapered axles work just fine if maintained properly.

 

Oops, I missed that you had 4.88s. Here's a used one on Ebay: https://www.ebay.com/itm/394383695838

 

That eBay unit is from a ZERO feedback seller who just signed up - be careful!

 

Good point!

 

Here's another from a seller with lots of good feedback: https://www.ebay.com/itm/363414738298

 

Thanks guys. I'm going to have to do some more thinking about it but I now have a better grasp on what my options are. Thanks for your help!