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D44 Spider Gears Swap

Discussion in 'Flat Fender Tech' started by william_cj3b, Apr 23, 2019.

  1. Apr 23, 2019
    william_cj3b

    william_cj3b 3BOB driver Sponsor 2019 Sponsor

    Milton, FL
    Joined:
    Nov 17, 2003
    Messages:
    411
    Lazy question...

    I want to swap 19 spline spiders into the 3B for a full-float conversion. I pulled a set from a 3-series case. To get the cross-shaft out I had to pull the case out of the housing and separate the ring gear. Is the 4-series (5.38) differential going to be the same? Been too long since I messed with differentials...
     
  2. Apr 23, 2019
    oldtime

    oldtime oldtime

    St. Charles,...
    Joined:
    Aug 14, 2006
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    2,660
    Yes if you removed 10 spline side gears from an open D44 and plan to replace the side gears with 19 involute from another open D44.
    Only the open cases and the side gear splines will be different.
    Differential case series does not effect swapping of the side gears in this instance.
    30 spline side gears is another concern.
     
  3. Apr 23, 2019
    47v6

    47v6 junk wrecker! Sponsor

    Washington DC.
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    Oct 25, 2006
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    will the 30 spline side gears work for the same purpose?
     
  4. Apr 23, 2019
    william_cj3b

    william_cj3b 3BOB driver Sponsor 2019 Sponsor

    Milton, FL
    Joined:
    Nov 17, 2003
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    411
    Thanks for the reply. You confirmed my understanding that the 19 and 10-spline side gears are interchangeable (with matching shafts).

    The lazy part of my question is "can I get the cross-shaft out of the 5.38 geared case without removing the ring gear?" Maybe you answered that already and I'm too dense...:oops::shrug:

    Others will have to confirm, but I think the 30-spline gears require a different case and the case uses different bearings from the 10/19-spline cases.
     
  5. Apr 24, 2019
    oldtime

    oldtime oldtime

    St. Charles,...
    Joined:
    Aug 14, 2006
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    2,660
    FWIW there are several different Dana 44 differential cases.
    3 basic types were manufactured...Standard Open differential case , Powr Lok and Trac Loc.
    Parts between these 3 types do not interchange.

    The D44 case series III @ 3.73 and lower ratio or series IV @ 3.92 and higher ratio only effects the fitment of the ring gear inside of the carrier.
    The carrier is the cast portion of the axle weldment which also includes the axle tubes, spring perches etc.
    Again the case series effects nothing else other than the amount of ring gear offset.

    The earliest D44 open cases were all assembled with side gears having 10 mill cut splines.
    In late 1956 the side gear and axle shaft spline was changed to 19 involute type splines.
    The 10 or 19 spline side gears can be interchange within the cases.
    In theory one could build a Dana 44 axle assembly with one axle shaft having 10 splines and the other axle could have 19 splines.

    In late 1969 Jeep CJ first started using the 30 mill rolled type splines.
    All 30 spline side gears require a different case due to side gear bore.
    Also the carrier journals have a larger I.D. which mandates a larger cone roller I.D.

    Pre 1957 Jeep Dana 44 rear axle shafts all have 10 straight cut spline rear shafts.
    They measure 1.225" outside diameter.

    Post 1956 Jeep Dana 44 rear axle shafts all have 19 involute spline axle shafts.
    They measure 1.245" outside diameter or .005" under 1-1/4".

    Post 1970 Jeep Dana 44 use 30 count rolled spline axle shafts.
    They measure 1.285" outside diameter.

    GROUP 21-03
    52979-----------------D41 / D44 (10-19 spline) differential carrier cone--25577
    52980-----------------D41 / D44 (all) differential carrier cup----------------25523
    805311----------------D44 (30 spline) differential carrier cone-------------25590
     
    AtomicYJ likes this.

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