How can I know if my Dana 44 rear axle is a 19 or 30 spline?

I am in the process of doing some upgrades to my 1969 CJ5 V6 and 1 of the things I wanted to do is install a rear locker. Since I am not a heavy duty rock crawler I checked around and liked the Auburn Gear Etched Locker #AUB 545019. When I spoke with the sales rep about my Dana 44 he told me the spline count was in fact 30 and the locker would work. He suggested since I was installing a new locker that I replace the ring and pinion and get a rebuild kit. He also suggested replacing the axles with new Chromoly 4340's from Yukon Gear. Now I have all the parts for a 30 spline rear end but now after doing my own research and a little help from Ryan I have serious concerns about what the sales rep was talking about. If what I found out is correct the 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. I know I am being overly cautious here because I definitely don't want my mechanic to get into the axle rebuild and find out it doesn't work. I have also been told even if I did get everything installed in the housing the new 30 spline will not work with the output shaft. Another person suggested I find a 30 spline axle 70/71 and it rebuild or locate a 3 series 3:73 19 spline open shaft Posi-Loc. I am so confused right now I really don't know how to proceed. I know the only way I can put in any kind of locker is with a 30 spline axle according to Herb on his site. If you have any advice for me so I can proceed please let me know. jeep toss

 

I believe that Eaton makes lockers for both 30 spline and 19 spline Dana 44s.

 

The sales rep has most likely sold you components that won't fit/work with your rear axle, if indeed it is still the stock 1969 Dana 44, offset, which uses 19 spline tapered axles. Tapered axles have a nut on the wheel end of the axle shaft.
If you do a search, one for Dana 44 tapered, and another for Dana 44 flanged, the differences will become obvious.
Flanged axles will not work in a tapered axle housing. A search would show that as well.
The simplest way out for you might be to purchase a 19 spline Power Lock for your axle ratio, and then re-use your current ring and pinion.
If you are lucky enough to source a used, flanged axle assy from a 1970 - 1971 CJ5/CJ6, you can expect to invest anywhere from $500 to $2000 depending on your build desires.

http://www.earlycj5.net/forums/showthread.php?109412-Building-an-offset-flanged-44

 

If your rear axle has a dustcap and/or a large nut on the outside end of the axle, it is a 19 spline. If the end of the axle is a flat disc then it is likely a 30 spline. A 30 spline locker will fit in an early D44 that had 19 spline axles, but you would have to switch to 30 spline axleshafts if you currently have 19 spline. If you aren't planning on any hardcore wheeling and you now have 19 spline axles, I'd just use a 19 spline locker, if you can find one. I'd be a little surprised if you can actually get an Ected diff in 19 spline. I know Detroit makes them. If you can swing the cost I'd highly recommend a selectable locker over an automatic locker. I see from your avatar you have a '69 CJ. There is a good chance that you have a 30 spline rear axle if that is correct. That said, a lot of things can change over the 40+ years of that Jeeps life. Best to positively ID the axle before you buy parts.

 

jpflat2a: I am using 30 spline axles in a 1961 vintage D44 offset housing. However it is a full floater. That may make a difference. I was assuming that you could use flanged axleshafts in a 19 spline housing as long as you changed out the case to 30 spline. Is the end of the axle tube different between the two?

 

No, stock 30 spline axle shafts will not fit a tapered axle housing or vice verse. The housing ends/axle bearings are completely different. If they would I would have been producing a kit for the last 20 or so years. The full float kits will interchange with the case/side gear change and the addition of two bolt holes added to the spindle flange. But that's because you don't have an axle bearing and seal difference to contend with.

 

My advice. Call your sales rep, send the Ected locker, and the alloy shafts, and the gears back. Take your refund money, buy a 19 spline Powr Lok, and save the rest, for any worn out bearings your installer finds.

 

That's my plan! I wish I knew about this forum months ago.

 

I agree with all above posts.
Identify, then disassemble and inspect before you make a decision or buy any parts.

If this is not an agressive offroad machine then stay with the current axle assembly.
The "Powr Lok" Limited slip differential is likely optimum for your needs.

 

Mine are 19 inner/27 outer from a kit.
Are your axles custom made or come from a FF kit?
Yes, the housings are different.

 

do they even make alloy shafts for the dana 44 off set flanged axle?

 

Warn used to make a chrome-moly axle set for the D44 - they were a flanged style and 19 or 30 spline FF kit.

 

In my 48 cj2a with a dana 41 with tapered axles I have a Lock rite locker and I have had no problems or complaints other than the noise and clanks when turning sharp. but I haven't been stuck or even close with it. and haven't broken it yet but my jeep is stock.

 

When did Warn make a flanged alloy axle for the CJ 44? The FF in both 19 and 30 spline yes. I never saw the. Listed in the catalogs and at one time the shop I work for had the largest in-stock Warn axle inventory on the west coast.
Not saying they didn't make them, Mike Warn had Warn Industries do some cool one-off stuff, but I'd like to look into it.
They even made their own locking differential at one time called a Hy-Torq that used rollers like a one way clutch. Similar to the way the Warn Lock-O-Matic hubs operate.

 

R&P made my sjafts for me. 30 spline inners, 27 spline out.

 

They were offering them in 1999 when I called them to order a set cut with 10 splines for my D41-2. I bought the whole kit (axles. hubs, bearings, seals, etc.) for the rear FF, they are flanged like a late style D44. I think we also bought and installed some front axles. I also bought internal locking hubs for front and back. I have PDF of their sales literature stashed somewhere on my PC. If important, I'll send you a copy.

I am sorry now that I did not buy their disc brake caliper mounting brackets. I called Warn a couple years ago to see if they had any 'left over'. Of course they had none, but after a short conversation, they sent me a copy of the internal engineering drawing for the brackets.

I have enjoyed the contacts I have had with them over the years.

 

So you have a full float kit? That is far different than flanged axles.
Warn did make a solid hub for the full float conversion instead of locking hubs that they called "drive flanges" that simply replaced the locking hubs but they did not make a flanged one piece axle for their conversion to the best of my knowledge because they used internal hubs. We were one of the first and one of the last Warn axle dealers in the country. We even had engineers and reps talk to us before they started their kit as we were already building ff kits at the time. If you do in fact have one piece flanged axles please post up a picture and a pic of your paperwork as that would be an extreme oddity.

 

Nick -- You may be right - it's been 15+ years since this was installed, but I do have a flange on the axle that makes it look like a late style (flanged) D44. It may be that they did this because this FF kit was a one-off for my D41-2? We went through all this during the rebuild of the rolling chassis last year - which work I farmed out to a local shop. I guess I would have to disassemble the hub/axle, etc. to confirm how this was done, but I am not inclined to do so.

I will get a photo when I can and post here.

 

I don't blame you for not wanting to disassemble. If you could post a pic of the flange that should be enough. If it has a big "W" and 3 screws that is the dust cover for the drive "flanges" or "slugs". The axle would normally spline into these and would be covered by the dust cover with the "W". The 3 screws just hold the cover in place.
Not a huge one-off for the Dana 41. Only the axles would be different on the inner end. All the rest of the pieces would be the same as the 19 spline 44 kit. I'm surprised they were actually willing to do a 10 spline version. We always had to put 19 spline side gears in the 41 diff (yes it can be done).

 

Nick

It may be a while before I unpack the chassis and pull a wheel to get a photo. But I will do it and post it on this thread.

Cutting the 10 spline… I just called them up and asked them if they would do it. They said no problem, and shipped a big box of parts which we installed. I was a bit surprised myself, but I am pleased with their products and service. It really makes flat towing simpler.

Mike