Its Time! Doing a D60 and D44 axle swap!!! with gears/lockers [Opinions Needed plz].

[Political Puppet]

Ok, I think this is the right spot for this, I've had this Jeep going on 20yrs...being involved with no less then 4 diff rebuilds, replacements upgrades whatever got exhausting. Nothing worked, so frustration and a lack of ability made it so the Jeep sat. It sat for a while...Ive just recently been able to find the parts needed for the final solution. After years of reading every book and article I could find Ive purchased the doner axles for this final swap. A center drop D60 and a passenger side dropped Dana 44 . It should be noted that I previously had a chance to salvage a wrecked scout or old J series truck that had been burnt beyond really any type of "real" recovery save for these lockers and gear set, that I just rolled the dice on really, cutting the axles free with a sawzall I took a chance and it paid off thankfully. Not knowing how much they would save me in the long run. I paid 200$ for these tops, basically (fuel, time and a few blades) then I just shelved them at that time as a few weeks after that salvage I had my first son and almost lost my hand in a industrial accident at work. Fast forward 10yrs...Ive done what I know how to do. Ive done my research, I know what I have on my shelf and I know what I need to get this done. I'm now ready, to finish this. At any cost. :drool:


Here comes the questions, forgive my ignorance and/or perceived arrogance, it is just passion and a desire to get it right. Thank you all, in advance!


Puppet

 

[Political Puppet]

So, after everything Ive ever read I assumed foolishly it seems that I would need to cut and narrow my rear axle housing on both sides and the long tube on the front Dana 44 ...imagine my surprise when I got home and just roughly positioned my new D60 behind my CJ...

This is known to be out of a mid to early 80s Dodge pickup. Thoughts?...
The whole 'housing narrowing' has been a reoccurring nightmare for me over the years, is this necessary? I'm trying to get 2 rims to get a better idea of the space needed.. I live in Canada and it seems this has become a lost art. Ive only maybe 3 shops in my area that even list this as a service they do, most want me to drop 2-3k on a custom build bolt in unit. That's not going to happen. If I got to go learn to do the job myself at some trade school, that's what I'll do. Thoughts?...opinions?...recommendations?
Last time I drove this Jeep turning was an issue as it had big ole 33 super swampers on it that rubbed the inside wheel wells and the leaf springs, so that's an issue needing to be addressed as well. The Dana 44 seems more straight forward (I jinxed myself didn't I?) in regards to the fact its like 6-8+inches too long for the front as my entire body width is 5'9"...and the Dana 44 was at like 6'6"-6'7" just rough measurements as I'm getting my wife to help me.

Thanks for the advice,
Cheers

Puppet

 

[Kane]

So did the front Dana 44 come out of the scout? If so then look up a thread I wrote on cutting and turning the inner Cs for proper caster. With the scout 44 it has to be done. I have mine at 8 degrees and my Jeep drives and tracks amazing.

 

[Political Puppet]

So did the front Dana 44 come out of the scout? If so then look up a thread I wrote on cutting and turning the inner Cs for proper caster. With the scout 44 it has to be done. I have mine at 8 degrees and my Jeep drives and tracks amazing.

I should have been more clear, sorry. I got the lockers and gears from the salvage, the housings I took them out of got ruined when someone I knew tried to narrow them, they were both junked. This Dana 44 comes from a 75 Jimmy I got on CL for cheap. I paid $300 for both the Dana 44 and D60 in working condition. Yes, thanks! I had overlooked doing a few quick searches for my questions, but then again, if I did that I wouldn't meet anyone.

Cheers,

Puppet

 

[tarry99]

I should have been more clear, sorry. I got the lockers and gears from the salvage, the housings I took them out of got ruined when someone I knew tried to narrow them, they were both junked. This Dana 44 comes from a 75 Jimmy I got on CL for cheap. I paid $300 for both the Dana 44 and D60 in working condition. Yes, thanks! I had overlooked doing a few quick searches for my questions, but then again, if I did that I wouldn't meet anyone.
Cheers,

Puppet

First off Welcome Aboard.......on the axles the Dana 44 is pretty common swap. 6 or 8 Lug.....and normally about 69" wide..........The D-60 can be all over the place and probably an 8 lug and width wise just don't know.........
The width of your Dana 30 narrow track up front should be 53" and the rear narrow track 50.5" WMS Wheel mount surface to Wheel mount surface........

So your going to have to decide on wheel options or will you be converting these all back to 5-lug?...........likewise you need to decide how wide you want this rig............and that would include your wheel and tire choice which ultimately will tell you how much you have to narrow each end...............Most axles are about 1" wider tire track in the front as compared to the rear and there is a reason for that!................Width will also tell you whether or not your springs will have to be out-boarded on your chassis........Lots of good info on the internet about axle choices and types including how to narrow them..........Lots of decisions need to be made.

 

[Peanut Butter]

Here is a thread you might find interesting: Dana 60s - Jeep-CJ Forums

 

[gert]

this should be a good thread.... my wide track Dana 30 had a wheel mount- wheel mount of 55 inches, I think that Chevy 3/4 ton is a 68/69 inch. I am in the process of narrowing a Dodge Dana 44 to 60 inches. You definitely want to figure out brakes and bolt pattern you want and the buy 2 wheels and tires that you plan to use and the start measuring on the jeep That is how I settled on 60 inches. Also I see that your tape measure goes to the end of your locking hub, make sure all your measurements are to wheel mounting surface that is the one that everybody bases theirs on I cant wait to see what you come up with

 

[Hedgehog]

Just wondering, what kind of locker do you have? The images show the ring gear on the carrier, but not the other side where the locking mechanism would be for identification. From my Limited experience the carriers look like Limited slip units, not actual lockers. Like I said, the pictures sparked my curiosity button that's all.

 

[Political Puppet]

Just wondering, what kind of locker do you have? The images show the ring gear on the carrier, but not the other side where the locking mechanism would be for identification. From my Limited experience the carriers look like Limited slip units, not actual lockers. Like I said, the pictures sparked my curiosity button that's all.

Ok, I took a few more pics, hope these are better. Maybe you can tell me, like I said I'm going on the word of other people so I'm not exactly sure...and thanks! Should I be concerned with that little bit of surface rust dust? I've been soaking them with the gear spray there. Just curious

Oh and those universal joints I recovered too, If I cant use them and someone can, hit me up. All the clips and grease nipples are there.

 

[gert]

They both look like at least a Limited slips not sure what type tho


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[Political Puppet]

First off Welcome Aboard.......on the axles the Dana 44 is pretty common swap. 6 or 8 Lug.....and normally about 69" wide..........The D-60 can be all over the place and probably an 8 lug and width wise just don't know.........
The width of your Dana 30 narrow track up front should be 53" and the rear narrow track 50.5" WMS Wheel mount surface to Wheel mount surface........

So your going to have to decide on wheel options or will you be converting these all back to 5-lug?...........likewise you need to decide how wide you want this rig............and that would include your wheel and tire choice which ultimately will tell you how much you have to narrow each end...............Most axles are about 1" wider tire track in the front as compared to the rear and there is a reason for that!................Width will also tell you whether or not your springs will have to be out-boarded on your chassis........Lots of good info on the internet about axle choices and types including how to narrow them..........Lots of decisions need to be made.

this should be a good thread.... my wide track Dana 30 had a wheel mount- wheel mount of 55 inches, I think that Chevy 3/4 ton is a 68/69 inch. I am in the process of narrowing a Dodge Dana 44 to 60 inches. You definitely want to figure out brakes and bolt pattern you want and the buy 2 wheels and tires that you plan to use and the start measuring on the jeep That is how I settled on 60 inches. Also I see that your tape measure goes to the end of your locking hub, make sure all your measurements are to wheel mounting surface that is the one that everybody bases theirs on I cant wait to see what you come up with

Thank you for the warm greeting! Yes its exciting, and thanks for your time, everyone I greatly appreciate it. Ill re measure. Then do some photoshopping and repost. I do realize I'm running the tightest fenders so I could go wider with those...if need be. I'm still waiting for a call back from the 3-4 shops I left messages at. I'm thinking on going 8 x 6.5 (16" tires) but am willing to hear any opinions for or against this choice. I figure Id only need to pay for the one conversion [6 to 8] as opposed to doing 2 [6 and 8 to 5] I used to generate a fair amount of wheel spin when Id put my foot into it and 8 bolts holding my tires on seems more 'comfortable' then 5. Plus rims are everywhere, tires are ultra common/available and I can go with el cheapos or a military type tire when the time comes. But hit me with the pros and cons. Plus I have some of the axle outer parts from the breakdown of the salvaged D60 I was hoping to be able to use. Ill post pics when its light out Id like to drop the drums in the rear and add disc brakes while its open, assuming [I know I know, big mistake] its not a $500+ bill, even then Id debate it. Disc brakes all around will go a long way to stopping my 360s legs...cuz they like to run.

Thanks again!

Puppet

 

[Political Puppet]

Here is a thread you might find interesting: Dana 60s - Jeep-CJ Forums

Thank you Sir!



Puppet

 

[Lumpy Grits]

If you could show a few detailed pictures of the both side of those diff carriers. Pretty sure someone on this forum can ID'em for you.
Look'n forward to you built thread.
Do you have any SMOG or other concerns where you live, that you have to comply with. Where I live, I have to SMOG test my Jeep every 2 yrs like it was new.
LG

 

[Political Puppet]

They both look like at least a Limited slips not sure what type tho


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Keep in mind these are old, 15yrs or more since they where available to buy...actually closer to 20yrs.

Puppet

 

[Lumpy Grits]

That doesn't mean there's anything wrong with'em.
I'm not sure. But they look like early Glesson Torsen carriers.
They are called Limited Slip Differential(LSD). The early ones would go from LSD to fully locked, depending on wheel spin/slippage.
LG

 

[Posi]

I would recommend staying with the 8 lug. Your swapping in beefy axles I wouldn't make then any less by downgrading to 5 lug.

I'm running 17" H2 rims. I found 5 aluminum rims for $100 on CL. If you generate a fair amount of wheel spin the 17" tires will give you less wheel hop getting into the skinny pedal. 15" work better in sand/mud.

I would also recommend replacing the rear drums for disc for weight loss, and efficiency. I used K-20 front discs on my rear and purchased the caliper brackets on ebay.