Dana 44 gear setup

idiocrates · Post by **idiocrates** » Tue Oct 13, 2009 7:19 am

Does anyone have any good pictures of their gear setup pattern after a differential over haul? I've looked at numerous "sketches" at various web sites on-line but none of them seem to match the pattern I've come up with. I know my backlash is too close right now coming in at a whooping 3 thous but the pattern I'm getting seems to be running a bit high on the tooth and all the way from the heel to the toe. Tonight I'm going to adjust the carrier shims to move the ring gear away from the pinion but I'd sure like to see some actual pattern pics before I make too many more adjustments. Thanks.

weasel · Post by **weasel** » Tue Oct 13, 2009 8:57 am

Yes that would be helpful as I am about to do this also

Post by **wesk** » Tue Oct 13, 2009 12:32 pm

http://www.differentials.com/install.html

http://www.precisiongear.com/pgtechpatterns.htm

http://www.scribd.com/doc/9375619/Dana- ... tion-Guide
Sign up here and download this guide for free. Nice PDF 16 page guide.

idiocrates · Post by **idiocrates** » Tue Oct 13, 2009 1:11 pm

Yes, sir.......I've seen and read the documents at the first and the third links and I've printed out the pdf from Yukon Gear and Axle.....I'm begining to believe my biggest mistake was believing those sites that said you could use grease as a marking compound. Maybe a trained mechanic can.....but the patterns I'm seeing are nothing like the scuff patterns indicated in these documents. I think grease will adhere to itself and pull away from areas where it would have stayed in place had it been something like prussian blue. Consequently I don't see a scuffing pattern I just see a bare tooth from heel to toe and face to flank.

I tried to get some prussian blue but so far every place I've been has told me it obsolete and nobody carries it any more. Worse comes to worse I'll order some on-line from Permatex.

Oh yeah.....and weasel.....when you read that part about having, getting, or making a set of carrier setup bearings......believe it! I tried to get a set from Precision Gear after I destroyed my old bearings taking them off and they told me they were back ordered 60 to 90 days. I bought two extra 25577 cones and then spent three days "ruining" them with a brake cylinder hone. I didn't think I was ever going to get to the easy on-easy off part but I finally did and man, oh man has it paid off. One of the other good points they make.....get a regular heavy hex nut to fit your pinion. If I had been using the self-locking permanent nut I don;t think I would have any threads left on the pinion by now.......and I'm still not through!

Just like everyhting else on this jeep......its an exercise in patience....and a heck of a lotta fun. Good luck!

oilleaker1 · Post by **oilleaker1** » Tue Oct 27, 2009 9:19 pm

They usually give you white lithium grease which is easier to see/use in the kits I've bought. Once you get it centered and looking good on the thrust side, with the pinion shims, you then adjust backlash by moving the ring. Hold the ring when you turn the set to apply pressure when you travel through the grease (both ways). Your pattern will be better. I usually do 6-8 teeth with the grease. You probably are already done, but I just read your post. John

idiocrates · Post by **idiocrates** » Wed Oct 28, 2009 6:51 am

Thanks for the reply.......I am indeed finished with the axle rebuild. I managed to get some prussian blue from Grainger and it helped (and worked) a lot better then the greaase ever did. I just about wore out the threaded part of my pinion shaft and almost ran out of inner pinion shims but by golly I think I finally got a pattern that will work. Its well centered between the face and the flank of the tooth but just a little bit more towards the toe then the heel. I ended up with .004 in the backlash setting and figured this was probably about as good as it was going to get. For me......the most difficult part of the whole rebuild was getting the pinion preload set. I don't have an inch-pound torque wrench and used the old breaker bar and fish scale solution to set my preload. I know......not a very accurate solution.....but it worked. According to my calculations my pinion preload is around 21 in/pounds.

Now only time will tell. And for all the begging I did to get pictures of other people's setups......guess who didn't get a single solitary picture of his final setup? I almost took the cover off and redid the marking just for the record but at that point I decided it was much simpler just to think about it, laugh about it, and forget about it!

Now all that remains to be done is a brake job and I'm good to go. Got the new inner axle seals installed.....new cones and cups on the axle.....new grease seals....new gaskets.....and ended up with a .002 in the end play category. Should finalize the axle this weekend and have it back under the jeep by Monday......I hope.