Dana 44 cut and respline

[Joruus]

Im putting a Dana 44 onto my CJ2 and it's too wide. I've already pulled it apart and am looking for recommendations on an inexpensive machine shop that will cut and respline in southern California. Any advice?

 

[Torxhead]

Joruus, I had Tri-County Gear once build me a Dana 44 , years ago for my CJ and have been quite satisfied with it. They are located on 2nd street,Pomona, I believe. Check their website. Quality isn't cheap either.

 

[Posi]

You may want to find another shaft so they can cut you a trail spare. I had a 44 cut down they wanted $80 for one and $120 for 2. I felt buying two was money well spent.

 

[Jimbos76cj]

Try made CJ width 44's. I know the whole axle is hard to find but could you cut the axle down to match the stock CJ width and buy ones that are already made?

 

[CJ007]

I don't know what they run but you can also buy cut to fit for custom width.

Search Results cut to

 

[73CJ]

I'm running a narrowed Waggy front Dana 44 . Cut 4" off the passenger side. Superior Axle resplined it. Recommended. A spare? Well maybe, but if I break one side, I'm not going carry both and not a rear as well. There will be more damage than just an axle shaft. . .

 

[Posi]

I should have included that I already had the extra shaft and while I was cutting down the original I had my extra cut down for $40. Seem to make sense to me, it would save me paying a higher price along with the time to search for a new shaft then have it cut down if/when I broke the original. With the extra shaft my rig wouldn't have much if any down time.

 

[Joruus]

I found a shop in la habra that is cutting and splining the axles and housing for 300 total. 50 each axle plus 200 for the housing. Not a bad price so I am going with them. Thanks for allthe advice, I think a trail spare is a great idea and will do that too.

 

[73CJ]

If you have welder and a chop saw, don't be afraid to narrow the axle housing. Lots articles on the net on how to do it.

Basically you cut the pass side only. About 4". Grind the weld from the knuckle. Measure 4" from the end of the tube (measure from the inside). Chop saw the tube. Remove the short piece from the knuckle and smack the knuckle back on the axle housing assembly. Line up the knuckles with an angle gage and weld. If you don't trust your welding, tack it and take it to a pro. The casting needs to be preheated prior to welding.

$200 seems pretty high. $50 for Resplining is about average. You tell the shop how much you cut off and they will take the same amount off.

A man needs to know his limitations - Clint E.

 

[CJ007]

If you have welder and a chop saw, don't be afraid to narrow the axle housing. Lots articles on the net on how to do it.

Basically you cut the pass side only. About 4". Grind the weld from the knuckle. Measure 4" from the end of the tube (measure from the inside). Chop saw the tube. Remove the short piece from the knuckle and smack the knuckle back on the axle housing assembly. Line up the knuckles with an angle gage and weld. If you don't trust your welding, tack it and take it to a pro. The casting needs to be preheated prior to welding.

$200 seems pretty high. $50 for Resplining is about average. You tell the shop how much you cut off and they will take the same amount off.

A man needs to know his limitations - Clint E.

Good call, I was thinking it was high myself. Not everyone can or will do their own but rep to you, that's a great point and straightforward.

 

[Posi]

As 73CJ mentioned it isn’t hard to cut down your own tube it just takes some time on your part.

This is a NT wagon Dana 44 , I removed the long side spring pad and shock mount.







I cut the inner knuckle first and made the cut close to the weld to aide in the tube removal.



Final tube cut





I ground down the weld until I could see the separation between the tube and inner knuckle. You will see a definite separation I just wasn’t there yet when I took this pic.



I made two 90 degree cuts then punched out one half at a time.







I found it best to do the grinding outdoors.

 

[CJ007]

Nice pics Posi! I agree on the grinding, you can lots with a grinder but what a mess. Or then you end up on your back to check something out, and find yourself itching.

 

[73CJ]

http://www.jeep-cj.com/forums/f92/narrow-your-own-axle-home-12481/

Nice