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Setting up a D44 out of the Jeep

Discussion in 'Early CJ5 and CJ6 Tech' started by w3srl, Dec 19, 2005.

  1. Dec 19, 2005
    w3srl

    w3srl All-around swell dude Staff Member

    Port Orange, FL
    Joined:
    Nov 6, 2002
    Messages:
    4,275
    Has anyone here ever set up a Dana 44 rear outside of the Jeep? if so, any helpful tips or suggestions? I've done R & P swaps inside the vehicle, just never out on the bench.

    After going back and forth on the issue of putting a locker and upgraded brakes on the D41 in my flattie, I think I've just about decided to bite the bullet and just set up a 44 rear and swap it out as an assembly. This is going to be a semi-long-term project, so I'm in no particular hurry to get it all done.

    What I'm thinking about doing is this:

    * Acquire a suitable D44 rear (preferably with a 5.38 gearset installed)
    * Pull the brake assemblies off.
    * Pull the cover & axles, check for wear & damage throughout
    * Install new seals throughout
    * Install Lock-Rite or Aussie locker
    * Install rear disc brakes
    * Swap axle entire axle assembly

    Idears, fellas? :?
     
    w3srl, Dec 19, 2005
    #1
  2. Dec 19, 2005
    Evans

    Evans Former YJ owner

    Dallastown , Pa
    Joined:
    Oct 28, 2005
    Messages:
    128
    Either work on it on saw horses or on jackstands up on a bench ( I did the latter) makes moving around alot easier and you can spin the whole axle to work on the pinion or the ring gear. I've done a 44 , 30 and an 8.8. Buy or make set up bearings for the carrier so that you don't have to try and take good bearings off if something isn't kosher...
     
    Evans, Dec 19, 2005
    #2
  3. Dec 19, 2005
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
    Joined:
    Sep 22, 2002
    Messages:
    5,349
    Sitting on a stool with the axle on a set of jack stands works great.
     
    Mcruff, Dec 19, 2005
    #3
  4. Dec 19, 2005
    Chuck

    Chuck Sponsor

    Southshore Ma
    Joined:
    Sep 19, 2004
    Messages:
    1,463
    Steve, I prefer to stand when working so I made a frame out of 2x4s then notched the wood in three places to hold the axle securely, and then set it on two saw horses.
     
    Chuck, Dec 19, 2005
    #4
  5. Dec 19, 2005
    Patrick

    Patrick Super Moderator Staff Member

    Los Alamos, NM
    Joined:
    Sep 22, 2002
    Messages:
    8,360
    IMO, buy a Powrlok....
     
    Patrick, Dec 19, 2005
    #5
  6. Dec 19, 2005
    Ghetto Fab.

    Ghetto Fab. Member

    Atascadero, Ca.
    Joined:
    Jan 13, 2005
    Messages:
    512
    Sounds like you have a good plan. I hate working on rearends while still on the vehicle. Much easier to do on the bench, or jackstands etc... Take your time and do it right.

    Kevo
     
    Ghetto Fab., Dec 19, 2005
    #6
  7. Dec 20, 2005
    vanguard

    vanguard

    Herm said Powerlocks were made to fit the Dana 41. Probably the only option for the early axle.
     
    vanguard, Dec 20, 2005
    #7
  8. Dec 20, 2005
    66cj5

    66cj5 Jeep with no name

    NorthWest Indiana
    Joined:
    Sep 10, 2003
    Messages:
    2,084
    rebuilt mine out of jeep. didn't use setup bearings, used a bearing puller instead ($$$$ but worth it). other tools I used: home made puller (broke gear puller so I made a bigger one), numerous pry bars, and a torque wrench.
     
    66cj5, Dec 20, 2005
    #8
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