Need some expert opinion on my Dana 44

[dschwab]

Ok so in the rebuild process on my jeep I discovered some problems on my Dana 44 rear axle. They are as follows: There is a shotty patch job about 1.5" X 3 " that I am scared to look under, there is a 3 inch long crack going parralel to the axle tube, along with several other smaller cracks, 2 deep grooves where the u bolts once were, and some pretty sever pitting around the flanges on the bearing cup section of the tube. The local 4X4 shop said they cannot or will not re-tube the axle but will repair the cracks and damage. I am not so sure I want to repair it and have it happen again as opposed to making it better. So my question is have it repaired or swap in an 8.8 or somthing similar? What would you do.

 

[IOPort51]

this looks like it has been used hard, are you changing ratios? It looks like you are going to weld on new pedestals, is that correct ?

I say do the math. what gets you the axle you want for the least amount of coins? A lot depends of your plan and we don't know what it is. If I was going to run 35s on a 44 I would be looking at an axle truss and some 5.XX differentials, but some may argue that.

Ok so in the rebuild process on my jeep I discovered some problems on my Dana 44 rear axle. They are as follows: There is a shotty patch job about 1.5" X 3 " that I am scared to look under, there is a 3 inch long crack going parralel to the axle tube, along with several other smaller cracks, 2 deep grooves where the u bolts once were, and some pretty sever pitting around the flanges on the bearing cup section of the tube. The local 4X4 shop said they cannot or will not re-tube the axle but will repair the cracks and damage. I am not so sure I want to repair it and have it happen again as opposed to making it better. So my question is have it repaired or swap in an 8.8 or somthing similar? What would you do.

 

[dschwab]

I have Been running 35's for a while now but I am downsizing to 33. As for the gear ratio I do not plan to change it unless I go to the ford 8.8 rear end. They don't make 4.27 for it that I have found. As for the jeeps use it will be a street able hunting rig to get me wherever I need to go so I don't need extreme.

 

[Petescj]

I agree with IO, that axle has seen its fair share of abuse and beyond. I would toss that housing. Whats the matter with replacing it with another 44? That would seem to be the most cost effective way. From what you describe another 44 in decent shape would serve your purpose just fine.

I dont see an 8.8 being more of an upgrade other than disc rear brakes if you go that route. That combined with not finding the correct gears for it would make the choice pretty simple for me.

 

[Old Dog]

The Explorer 8.8 while being cheap and stronger than a 44 would be way wider than your narrow trak 44. (like 8")
You should be able to fine a N/T 44 pretty cheap. That's what I'd do.

 

[JR74CJ5]

with all of them...

Though, you can (if you have a welder and some skills) weld up any openings, (slowly so to not warp it... further.. ) and then spend your time trying to find a new 44 in better condition for cheap. At the most I'd only worry if hard usage through rocks, or through deep water crossings. At that point, if you cross water, and are not confident you got all the leaks, change the fluid after the water crossing and see if milky (water mixed). That will tell you if it will need to be a "every crossing" thing or not...

That would be the "wrong but acceptable" way of getting by a while on it...

I welded mine up, though it wasn't in as bad of shape as yours, it was still cracked...

http://www.jeep-cj.com/forums/f2/leaky-dana-44-crack-12692/index2.html#post101602



~ Jr

 

[IOPort51]

It is my observation that the most expensive part of an axle is the gears. So if you have to buy a new set for a new axle that is where the money will go. I think you can find another 44 if you look hard enough, they do not grow on trees, and if need be reuse the gear set you have unless they are badly worn or chipped.

 

[dschwab]

Thank you all for your input. After reading all of this I decided to stick with the stock 44. After scouring the web and making some calls I found an identical axle for $250 and ill be picking it up Sunday. And the best part is ill have lots of spare axle parts.

 

[73CJ]

And the best part is ill have lots of spare axle parts.

Always good to have spare parts. I've twisted a stock one piece Dana 44 with my AMC 258 i6 / 4.2l .