Dana 44 Knuckles

First of all, please forgive me for what I'm sure many will consider a stupid question that's already been discussed hundreds of times. Please don't tell me what an idiot I am, as I'm already fully aware. Honestly, sometimes I wonder how I ever got my Jeep this far along. I've spent hours researching the following question(s) and can only find bits and pieces of good answers. Before shelling out quite a bit of dollars on swapping in a Dana 44, I want to be sure that I understand my options, so that I'm not buying parts and spending time on things that won't work.

So here's the deal, my Jeep currently has a recently rebuilt 1979 Dana 30 with disk brakes, new hubs, and a locker. I've had a narrowed Dana 44 housing that I believe is out of a 78-79 Wagoneer sitting on my garage floor for about four years, and I'd like to get it swapped in within the next few months. I only have the D44 housing; no axles, carrier, ring & pinion, and no knuckles, brakes, or hubs...just the housing. What has me most concerned is trying to locate all the correct/compatible knuckles, brakes, u-joints, bearings, spindles, and hubs. However, this weekend, I acquired a set of knuckles that I believe to be GM flat top knuckles for a D44. From what I understand, these are desirable knuckles for those doing a SOA, but I am SUA, so I'm still questionable if they're that great for my application. I believe I have two options (please tell me if I need corrected):

Option 1: I think I can transplant my current CJ Dana 30 knuckles, brakes, spindles, and hubs onto the Wagoneer Dana 44 inner housing. However, the standard Dana 44 outer axle stubs won't work with the Dana 30 spindles. But, if I use Scout II outer stubs they will work with the Dana 30 spindle and hubs and still have the correct u-joint size for the dana 44 axle. If I can do this, the upside is that I already have most of the parts. If I'm correct, the possible downside is that the Scout II outer stubs are weaker due to less spline count than if I go with option 2. Am I correct?

Option 2: Use the GM flat-top knuckles. If I do this then I'm assuming that nothing is compatible with my Dana 30 currently on my Jeep, so I'd have to locate or purchase the GM calipers, disks, spindles, and hubs. If I'm correct, the upside is more strength (basically the whole point of the swap to begin with), but the downside is trying to locate all the associated parts for the GM which could be a costly pain in the butt.

If anybody in the know could help correct, reaffirm, or add to what I believe my options to be, I'd greatly appreciate it. I'd also appreciate any advice on which option to go with. Thanks.

My current Dana 30:
[URL="http://s280.photobucket.com/user/David_Eberhardt/media/Front%20Differential_1979%20Dana%2030/240%202_zpss4t2fdbn.jpg.html"]
[IMG]http://i280.photobucket.com/albums/kk181/David_Eberhardt/Front%20Differential_1979%20Dana%2030/240%202_zpss4t2fdbn.jpg[/URL][/IMG]


My Dana 44 housing
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GM flat-tops for disk brakes?
[/URL][/IMG]

 

First off, I don't think this is dumb because at least i don't know the answer. I have read that the d30 and d44 knuckles interchange. this may or may not be true. I read it here. Can you elaborate on the d44? did you narrow it? Did it come that way? how will you know what axle shafts to use? are they custom. I am asking more basic questions than you.

 

I got the D44 housing already narrowed to 40" from tube to tube, if that makes any sense. This is very close to my current D30 measurement from the same points. I would plan on buying custom length inner axles since I'd assume that there are no OEM applications that used this same narrowed length.

 

Hum, using dana 30 knukkle, spindle brake and scout outer can be done no probleme. But the scout outer axle is a 27 spline, same as the dana 30 from you're cj, but u-joint i dana 44 size. You still have a weak part that is the outer.

I you go with the Gm knukkle and you want to keep the 5x 5.5 bolt patern you can buy this kit and it's a bolt-on kit. You only missing the outer shaft that is 19 spline (bigger than the scout 37 splin. So you will have a true dana 44 from wheel to wheel.


here the kit
http://www.tomsbroncoparts.com/product/disc-brake-major-kit-dana-30-44-prop-valve-bracket-warn-hubs-wheel-bearings


You can diy the part at a local junkyard.
You will need gm small spindle spicer 706528X
You need the galiper braket from a gm k1500 72-86
Two galiper from gm k1500 72-86
Two hub from a 1985 f150 with dana 44
Stub shaft 19 splines (gm/dodge/ford dana 44)

 

Hum, using dana 30 knukkle, spindle brake and scout outer can be done no probleme. But the scout outer axle is a 27 spline, same as the dana 30 from you're cj, but u-joint i dana 44 size. You still have a weak part that is the outer.

I you go with the Gm knukkle and you want to keep the 5x 5.5 bolt patern you can buy this kit and it's a bolt-on kit. You only missing the outer shaft that is 19 spline (bigger than the scout 37 splin. So you will have a true dana 44 from wheel to wheel.


here the kit
http://www.tomsbroncoparts.com/product/disc-brake-major-kit-dana-30-44-prop-valve-bracket-warn-hubs-wheel-bearings


You can diy the part at a local junkyard.
You will need gm small spindle spicer 706528X
You need the galiper braket from a gm k1500 72-86
Two galiper from gm k1500 72-86
Two hub from a 1985 f150 with dana 44
Stub shaft 19 splines (gm/dodge/ford dana 44)
Two manual lock 19 spline (gm/dodge ford dana 44).



All this item are the same as the kit i link you up there.

 

This is awesome!

 

Option 1 as you list it is correct in that it will work. I have run several 44 axles with the Jeep Dana 30 outers and Scout outer shafts and never had an issue. Dutchman will build you a complete set of axle shafts for a reasonable price if you have any worries about strength.
http://www.dutchmanaxles.com/

 

Yeah but you still have the 6 bolts lock. For the same price he will have an internal lock that is way better than the CJ and scout manual lock. You also have a bigger outer shaft. I've have done 250 trail trip in the last 4 year and since i have the scout dana 44 the only think that broke is either the 6 bolt or the lock.

My 2 cents.

 

Here is a reasonably good site for D44's
http://77cj.littlekeylime.com/flatop_knucles.html

I tossed around front axle options for my B for about 3 years and finally decided to go with the Scout outers/disc brakes. I used a widetrack CJ housing from R & P, Dutchman axles-off the shelf WT replacements, and Reid knuckles. The Reid knuckles are drilled for the Chevy TRE's and the tie rod sits above the steering arms. I'm using those with a high steer arm for the drag link.

And yes, the 19 spline outer shafts are stronger than the 27 spline versions as is internal versus external locking hubs. On the plus side, the Scouts use an 8 hole spindle mounting. My thoughts were/are that I'm highly unlikely to ever break one of Dutchman's 27 spline outer axles shafts and if something has to break, I would just as soon have it be the locking hubs-I do carry a set of drive flanges for a trail fix.

 

All the good advice is appreciated. It was difficult to weigh options when I didn't even fully understand what my options were. You guys have cleared it up quite a bit. I'm still uncertain, but at this point I'm leaning towards using the Dana 30 knuckles and Dutchman axles. I still need to research how hard or expensive it will be to do the GM knuckles before I completely decide.