Dana 44 Rear Differential

idiocrates · Post by **idiocrates** » Mon Aug 17, 2009 5:46 pm

Okay.....I guess I should have looked at this while the axle was still out of the vehicle but since we had been driving the jeep without any problems I kinda figured this was all right. Well.....I may have been wrong. Please, gentlemen......any comments?

Compared to the dana 25 up front this ring gear looks terrible, but having never seen a new one or even a good worn one I thought I'd see what you guys think. Thanks.

Post by **wesk** » Mon Aug 17, 2009 9:53 pm

You need a new ring and pinion gear set.

idiocrates · Post by **idiocrates** » Tue Aug 18, 2009 7:24 am

Yeah, I'm not too surprised but just looking at the price of a new set of gears this is probably going to be the next most costly repair after the engine. My question now is......is it possible to rebuild this differential without all the specialized tools indicated in the manual....like the c-clamp attaching dial indicator and the calibration blocks, the case spreader, and the bearing press arbor?.....cause I have none of this stuff.....and for this kind of money I may be better served by taking the axle to a professional. So, is there an alternative setup procedure? Thanks.

Post by **wesk** » Tue Aug 18, 2009 8:09 am

The only two items you always need are the hib puller to get her apart and the pinion setting gage to put her together. Everything else can be improvised. My recommendation to novice mechs and hobbyists is to farm the axle overhaul out. Or at least farm out the pumpkin assembly.

In your case I would recommend you shop for a good used 44. You can pull the rear cover and inspect for a good one. You can check bearings without pulling the pumpkin apart. You can change the pinion seal and gasket without disturbing the pinion setting/preload.

idiocrates · Post by **idiocrates** » Tue Aug 18, 2009 11:12 am

I'm thinking farming the specialty stuff out is the way i am going to have to go. I've read enough to know I'm in over my head although the procedure sound simple enough. Anyway........two final questions.....

1. This differential has the tag 43/8 on it indicating it has a 5.38 gear ratio. Is it absolutely imperative that I go back in with the same ratio....or could a 47/11 (4.27) gear set be substituted instead?

2. As long as I have to redo this thing would it be beneficial to install a locker in the differential and if so, what all gets replaced by the locker.....just the spider assembly?

Thanks.

Boomer573 · Post by **Boomer573** » Tue Aug 18, 2009 2:42 pm

I would "farm" it out to a professional. I am mechanically inclinded, but opted not to perform that surgery. I have done several on farm tractors, but tractors are more simple. Of course, I am going to pickup my axles tomorrow with a price tag of $2,500.00. I know they are done right. I don't have to worry for another 50 years, at that point my kid could worry about it. Be happy that you didn't have to replace the ring and pinion on a Dana 25. Mine was l500.00, and those things are getting hard to find. I was looking for parts on the Dana 44, O'Reilly automotive had rebuild kits (bearings and seals) for $100.00. The bearings and seal were of good quality, not the cheap China stuff.

idiocrates · Post by **idiocrates** » Tue Aug 18, 2009 3:43 pm

Thanks for the comments. I'd have to say I'm more inquisitively inclined then my mechanical ability would like to admit......or in other words......I can always take it apart.....its the putting it back together that trips me up. And its not that I'm not unfamiliar with the mechanical workings of a differential.....like you.....I've helped and even done one by myself through the trumpet opening on an "N" series Ford tractor......and it was even older then this jeep. But without a case stretcher or a pinion gauge I'm pretty much up a creek on getting this all correct......so I agree......maybe it can last another 50+ years....if its done right. I'm more willing to take that chance then betting on my by guess and by golly.

Post by **wesk** » Tue Aug 18, 2009 9:48 pm

I have rarely needed a case stretcher to get the ring gear out of a 44. The real trick that means long useful life to a ring and pinion is getting the setting right and there's only one way that can get done.