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build your own full float dana 44?

Discussion in 'Builds and Fabricators Forum' started by 47v6, Jan 6, 2015.

  1. Apr 24, 2015
    millennium falcon

    millennium falcon Member

    Central PA
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    haha that's funny, I have actually used the "paint can/plywood" method with great results. Except I didn't use the red oxide primer....I used sunrise red...so you might want to read they can to make sure it will give you the correct pinion angle.
     
  2. Apr 24, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    Alright, the calibrated sunrise red is the correct one?

    When I cut off my spring perches in the front i will definitely go for an angle finder and set that up correctly. Thats important for steering, the rear I am not so very concerned with. What is right? 1.5 to 3 degrees is what the link said. Thats great, but I also don't have a double cardan joint, have an extra 12 inches of driveshaft length and made my driveshaft myself out of some DOM and old driveshaft parts. Doesn't vibrate, didn't when I had no shim to give angle to the pinion either.

    The paint can and 3/4 plywood is a 7 degree pinion angle up from stock.. don't need an angle finder if you have a tape measure and a speed square and have been a carpenter. Seems the idea is to keep the pinion angle slightly down to counteract spring wrap.
     
    Last edited: Apr 24, 2015
  3. Apr 24, 2015
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

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    You could tack the perches on, where you think is right but, I wouldn't burn them in until the axle was under the JEEP where I could check and make sure I liked the angle. actually, I'm not sure I'd even tack them. I'd probably just wait until I was ready to install it in the JEEP, then set it where I wanted it. That way you're sure.
     
  4. Apr 24, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    you're right. that is exactly what I should do. I am impatient though. This project had taken a lot longer than I expected and cost a lot more money than I budgeted. Its ok though because its going to be cool. When I get to that point I am sure to cut off a shackle mount or something and re do that too. Nothing is permanent on my heep.
     
  5. Apr 25, 2015
    Mike C

    Mike C Member

    Austin, TX
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    You are obviously not new to working on stuff, so this should have been learned a LONG time ago! LOL
     
  6. Apr 28, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    I was going to copy the yukon bearing puller but decided I would buy a 30 dollar 2 jaw puller and modify that. I made a button to push against that is shouldered to fit inside where the axle goes into the case so it can't push off center. The d44 case has 2 recesses where the jaws for this puller fit into with a bit of grinding. I used my impact wrench and voila, came off with no issue and did not damage the bearings at all.
    [​IMG]
    I then took the bearings off the old case and made some set up bearings to use on the powerlok case. I chucked them up in the 4 jaw and indicated it in. I then used a boring bar with a carbide insert to cut the ID. worked great.
    [​IMG]
     
  7. Apr 28, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    USA standard gears are made in India. These are just oxide finished, don't look like they are lapped or anything.
    [​IMG]
     
  8. Apr 28, 2015
    tarry99

    tarry99 Member

    Northern California
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    That's about the only place in the World anymore that has the equipment and Manufacturing ability (without the EPA crawling up there butt) to build that stuff. I have heard a few negative things but equally I have heard just as many good things about the quality..........Lot's of bearings and other Items coming out of there that are American Brands being repackaged...........Vietnam is the next place for the Industrial Revolution!
     
  9. Apr 28, 2015
    millennium falcon

    millennium falcon Member

    Central PA
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    Are you going to have her together in time to bring it up to pa this summer?
     
  10. Apr 28, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    I could probably have it together in a couple days if I didn't do anything else. I am taking my time with this because, well I never have spent this much money on any one component of a vehicle before. I'm really cheap. I will also be cutting off my old shackle mounts when i install this assembly. I don't like whats there now. That is just really couple hours of work though ,if I buy them ready made. If I make them myself it will be a a day.

    So, yes. I should be done in a month or less. I drive it every day as it is with the tapered axle right now with no problems.
     
  11. Apr 28, 2015
    45es

    45es Active Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    And you said in another thread " I was looking hard at an overdrive, but with 35" tires I just don't need it unless I am going on the highway. Thats not going to happen." Does this mean that there may be a road trip in your future? ;) The overdrive just may be your next expensive part to buy. lol
     
  12. Apr 29, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    Yes, I am going to drive to this nice place in Washington State. Its called Naches and is on the other side of Mt Ranier from where i used to live 15 years ago.... hahahah.

    I drive it every day now, but Its not a safe vehicle over 50mph. Its not even the Jeep, but everyone else. People are insane here and are truly trying to kill me when I drive or walk anywhere. They aren't even aware most of the time because they are texting or in a hurry or just straight up A-holes.

    I can get 50 mph in 3rd at about 2700 rpm with out the OD. It might be nice for a bit more than 1st off road. 1st, not low.
     
  13. Apr 29, 2015
    jeepermc

    jeepermc Active Member

    Western WA
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    Let me know when and i'll meet you there!
     
  14. Apr 29, 2015
    45es

    45es Active Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    We can all meet at Jim Sprick Park. Just a mile down the road for me.
     
  15. Apr 30, 2015
    jeepermc

    jeepermc Active Member

    Western WA
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    Do I know you Ed? I'm there every year for PNW trail Jam and sometimes "Pick up a Mtn".
     
  16. Apr 30, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    I am glad i can be a matchmaker.hellokitty
    Look at what I didn't notice. I mean I really didn't notice this. new pinion on left.
    [​IMG]
    I need to buy the correct yoke for this new pinion since my old one isn't going to work,or maybe.......

    D30 yoke is the same spline count and fits. The exception is that the yoke is threaded for bolts whereas the d44 is through drilled. There is also a flange for a sort of dust cover that would go over the seal. Unless someone can tell me otherwise, i am going to use the d30 yoke.
     
  17. Apr 30, 2015
    millennium falcon

    millennium falcon Member

    Central PA
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    Fill in all the splines with your tig....and then use your newly acquired spline cutting skills to cut new splines for your old yoke. I literally cannot think of any issues with this method.....WWSD "what would Snake do"?
     
  18. Apr 30, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    I think that is a perfect method of overcoming this obstacle. I think Snake would just throw them through the closest window. I would do that, but a piece of wood caught in my table saw and ejected the dang thing at light speed right through that window and now is covered with a piece of plywood. If I were to throw that yoke into the plywood it would assuredly bounce back and hit me right in the forehead knocking me unconscious. Maybe that would be what I need to regain some sense?

    If nothing else it would be funny.
     
  19. Apr 30, 2015
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
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    Damn, I thought that was Captain Ron mehh

    H.
     
  20. Apr 30, 2015
    tarry99

    tarry99 Member

    Northern California
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    If it makes a difference..............The D-44 with the through holes that use U-bolts is much stronger than the other version with the threaded holes and straps that clamp the the bearing to the yoke.
     
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