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Dana 44 Overhaul

Discussion in 'Early CJ5 and CJ6 Tech' started by Elvislives, Apr 29, 2012.

  1. Apr 29, 2012
    Elvislives

    Elvislives Member

    College Station, TX
    Joined:
    Jan 22, 2012
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    186
    I think I'm going to give up looking for a good axle mechanic and rebuild my Dana 44 flanged axle in-house. I have all new timken bearings, seals, 11" brakes, posi, etc. ready to go.

    I've found some good step by step instructions that I'll post later and try to make this thread useful to others. I have a friend and his Pop who've done this to other axles and they have a dial indicator and some good experience. There's a few other tools, pullers I'll need but I'm tired of talking to so-called experts who say "just put everything back like it came out and it should be good"
    Those more experienced here may want to talk me out of this. If not, you will be subjected to numerous questions and constant harassment from a sales guy who thinks backlash is caused by picking up the newspaper on the driveway.
    Seriously, if you have links to accurate rebuild info, please share. I'll do the same. If this is redundant with other threads, please let me know and I'll delete. Otherwise, any/all input appreciated.
     
  2. Apr 29, 2012
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    Sep 23, 2002
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    12,529
    Do you have a Factory/Technical Service Manual? Lots of good info there. If you get hung up don't hesitate to post up.
     
  3. Apr 29, 2012
    Elvislives

    Elvislives Member

    College Station, TX
    Joined:
    Jan 22, 2012
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    Yes and it's pretty good. Thanks for the "if you get hung up" part. I'll be posting.
     
  4. Apr 29, 2012
    Elvislives

    Elvislives Member

    College Station, TX
    Joined:
    Jan 22, 2012
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    Question: can the 2 pinion races be tapped out with a punch?
     
  5. Apr 29, 2012
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    Yup. A brass punch is preferable to not score the bore. Be aware many times you damage the pinion depth shims doing it. If reusing the original gear set you can measure the old shim pack and install new. Should get you the same result. Use a micrometer if possible, not a caliper. A caliper isn't as accurate. Damhik....
    If you need to re-set pinion depth (different gear set) i have an inner race I ground down the outside so it just slips in and out for setting pinion depth. Keeps you from ruining the shims. You can grind the old inner race and it will get you darn close if not exact.
     
  6. Apr 29, 2012
    Elvislives

    Elvislives Member

    College Station, TX
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    Jan 22, 2012
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    I have a very good Starrett digital micrometer. (from my reloading days). That might be the best tool in my shop.

    Using same gears and will have questions about your answers later. You jumped into outer space on me :)

    Disassembly was easy except I need to find bearing pullers for the pinion and carrier. Off to buy brass punch set......
     
  7. Apr 29, 2012
    homersdog

    homersdog Tulsa, Ok 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Tulsa, OK
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    I hope you both keep posting (elvis and nick). I'll be doing the same work soon and I am following your comments.
     
  8. Apr 29, 2012
    grannyscj

    grannyscj Headed to the Yukon

    Anchorage, AK
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    To pull the case (esp if it is the original set of gears) you'll probably need a spreader. They are easy to make and many examples on the Internet. If using the same gears and case you'll be alright using the same shim packs but if you're changing the case to a new LS differential you'll need to do all the setup at least on the case. Pinion depth should be alright. If changing the case buy an extra set of bearings (don't need the races). Take a grinder to the inside of the bearing race to make them easy to slip on and off while setting BL and gear mesh. Much like Nickmil suggested for the pinion race.
     
  9. Apr 29, 2012
    Elvislives

    Elvislives Member

    College Station, TX
    Joined:
    Jan 22, 2012
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    186
    The pinion dropped into my hand when I pulled the yoke and lightly tapped it. So now the first boo boo. I'm not exactly sure if I know where all the spacers go. I've laid it out in these pics to show where I think they are positioned. One is not exactly a spacer, it might be the crush washer??
    [​IMG]

    [​IMG]
     
  10. Apr 29, 2012
    brunester

    brunester Member

    Santa Cruz Ca.
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    Aug 4, 2011
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    97
    That washer thing closest to the seal is the oil slinger.
    I dont think that the D44 has a crush washer, as the pre-load is set with shims.
     
  11. Apr 29, 2012
    brunester

    brunester Member

    Santa Cruz Ca.
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  12. Apr 29, 2012
    vsixbill

    vsixbill New Member

    Usa
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    Feb 26, 2006
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    There is a good article in this linkhttp://www.pirate4x4.com/tech/billavista/Gear_Setup/ . I set up a Dana 30 for my front axle, even though I had never done it before. It requires some special tools and lots of patience and some head scratching. There are no short cuts. I was not too concerned if I didn't get the backlash perfect( don't get me wrong,I did the best I could) because it being front axle not too much fast driving in 4x4. It can be done by jeep junkie buAt would be nice to have expert help for first timer.
     
  13. Apr 30, 2012
    Elvislives

    Elvislives Member

    College Station, TX
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    Jan 22, 2012
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    Yes, good info here. Thanks
     
  14. Apr 30, 2012
    Elvislives

    Elvislives Member

    College Station, TX
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    Jan 22, 2012
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    Related to my rebuild and installation of a powr-lok, this is a link to the Spicer Manual for the powr-lok,,,
    www2.dana.com/pdf/5315-3.pdf
     
  15. Apr 30, 2012
    djbutler

    djbutler Sponsor

    Rio Linda CA
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  16. Apr 30, 2012
    Elvislives

    Elvislives Member

    College Station, TX
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    Jan 22, 2012
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    I'm jealous. I've seen these on the web but can't justify for two axle rebuilds. I've posted in classifieds for used axle tools and hoping to see something from that.
     
  17. Apr 30, 2012
    grannyscj

    grannyscj Headed to the Yukon

    Anchorage, AK
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  18. Apr 30, 2012
    Elvislives

    Elvislives Member

    College Station, TX
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    I completely agree. Still need a puller to remove old bearings so I can make set-up bearings. :)
     
  19. Apr 30, 2012
    djbutler

    djbutler Sponsor

    Rio Linda CA
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    Be advised: the side bearing races they sell are for the later differential cases that use the larger bearings. I think (but not sure) that these are the size used in 30 spline axles. I know they are too large for 19 spline cases.

    Don
     
  20. Apr 30, 2012
    Elvislives

    Elvislives Member

    College Station, TX
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    I'll watch for this but I bought the kit from Randy's R&P and mine is a 30 spline. I spent way too much but hey, who's keeping track.
     
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