Postal Dana 44 Build

Ok so I have 2 postal flanged offset 30 splined axles and 3 of the long side axle shafts. The plan is to build one by cutting off and sleeve the short side tube to match long side axle shafts. Looks like it will come in around 53.5 WMS. Will be going in a CJ-7 with a wide track Dana 30 up front. Anyone done something similar? Any advice would be appreciated. I have been unable to locate the unicorn 86 D44 I would like to run thanks.

 

Can't you remove the short side tube, completely, and replace with one of the long side tubes instead of cutting and welding and sleeving? Better yet, save the off set flanged axles and grab a centered 44 out of the rear of a '72 - '75 cj5. Easy and not destroying good, sometimes hard to find axles. Honestly, I didn't know the off set 30 spline flanged was ever in a postal.

 

I will post up some pics this week of what I'm doing with the postal axles. The mail jeep axles of that era are not what a cj5 restoration would use but similar in design with different specs. The axles are about 3 inches different in lentgh.

 

I think if I tried to remove the long side tube it would get damaged but am open to ideas thanks in advance

 

There's lots of info on the web about removing axle tubes. Some are plug welded and, I think, some are just pressed in. I don't know enough about it to offer any further advice but, it may be worth a quick google search. Good luck.

 

Without the proper tools, I'd stick with your initial plan. I'm subscribed.

I built a narrow full float D60 years ago by using a rear from a quadratrac-equipped J-series truck with an offset FFD60. I essentially did what you are planning, but made both sides short, not long. I cut the long side down to match the short side and pressed it into the housing after getting the old piece out. I located a short shaft online for $30 on the FSJ forum.

Pressing the tube into the housing was a chore. I built a giant frame out of old I beams and, with heat, it took every last ounce of a 20-ton hydraulic jack to get that tube into place. It worked out great, but I'm not sure I'd ever attempt that again.

 

You might get some ideas from millennium falcon's thread:
Starting a project need some help Quadra track AMC 20

 

Thanks guys wil get some garage tine tomorrow and will take some pictures

 

Got some cutting done to get rid of spring over and shock mounts. Rough measurements of axle shafts show 2 7/8 difference in lentgh. Going for the sleeve and splice kind of thing.

 

Good stuff by the way. This is gonna be good.

 

Postal 44s are centered and not rare. Offset flanged 44s were only 70.5-71 years on the CJ5 and they are both sought after and fairly rare

Interesting you are widening an axle- opposite of most- who are narrowing them. Do you plan on using the centering tools for lining things up? Or does sleeving the tube mean things will line up on their own?

 

Will be checking with an bar and some spacers in the bearing seat before and after welding . From what I understand it is a little more critical on a rear axle to get things straight. I got the differential and axles in last night to check spline engagement with spiders. I need to trim off a little more of the tube to get the right length. Hope to get some garage time next Friday to play also doing house remodel. Thanks to ITLKSEV for the encouragement and advice I would like to see the Dana 60 full float building pics if you have any

 

I'll look. I don't think I do. That was back before digital cameras were affordable. I have pics of the finished unit, but I don't think I have any of the process. It ended up around an inch wider than the narrow-track Wagoneer D44 with 3/4 ton outers I used up front.

 

Got some progress going on axle with help from an old time jeeper here in San Luis county. Next up take it home and tig weld

 

This is REALLY cool.

 

^ That.

 

Got it welded up yet?