Dana 44 Cases

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440sixpack
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Dana 44 Cases

Post by 440sixpack »

I want to swap my 4.09 gears for 3.54 gears.

I've herd 3.73 and lower gears have a different case than 3.73 and higher gears. is this true or do they men they have different carriers ? I have 3.54 carriers as well as my 4.09 ones.

I don't want to order all the parts if this isn't going to work.
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HeavyMetalThunder_81
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Re: Dana 44 Cases

Post by HeavyMetalThunder_81 »

Just the carriers are different.
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Topic author
440sixpack
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Re: Dana 44 Cases

Post by 440sixpack »

Thanks. my 3.54 carrier is a 30 spline axle. I don't know what' spline count is in my rig at the moment but I assume a 1978 J10 would be 30 spline as well ?

There was a 19 spline Jeep Dana 44 but I don't know when or in what.

4bz
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Re: Dana 44 Cases

Post by 4bz »

The case is the same for all dana 44s, and the carriers are different to adjust for the size of the gears. The split between the different carriers occurs between 3.73 and 3.92 (3.73 down to 2.72, and 3.92 and up to about 5.38). If you have carriers that you know will work with 3.54 and 4.09 gears, then you probably have both the high speed (2.72-3.73) and low speed (3.92-5.38) carriers. If you push the two different carriers side by side, you can see a difference in the location (height) of the machined surface where the ring gear bolts on. There are also special gear sets that use an extra thick ring gear. These gear sets enable a low speed gear (3.92-5.38) to be run on a high speed carrier (2.72-3.73). The thick gear ring and pinion sets are not very common compared to the standard ring and pinion sets. For your swap (as you describe it), you will need to change the gears and the carriers. Pinion gears for the dana 44 can be found with both fine and coarse spline u-joint yokes, and you may need to also replace your u-joint yokes if the 3.54 and 4.09 splines are different.

4bz
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Re: Dana 44 Cases

Post by 4bz »

A 78 J10 should have 30 spline axles.

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440sixpack
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Re: Dana 44 Cases

Post by 440sixpack »

Very informative thanks. sounds like all I need is an installation kit and the gear set. I'll have a pro set the gears up that's something I've always avoided.

I have a nice set of factory gears on the 3.54 carrier , but I've been told it's nearly impossible to rest used gears and get them quiet. any truth to this ? I don't want any noise I'll be new gears if that's true.

4bz
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Re: Dana 44 Cases

Post by 4bz »

If used gears are worn evenly and without any unusual wear patterns, they can frequently be reused without any problems. If you are going to pay a professional to install them, I would go with a new set so you have a guarantee on the performance of the installed parts. Spending $800 or more to have used gears installed (with no guarantee) hurts a lot more than a job that cost only a few hours of your time (if you do it yourself). I believe that most installation shops will only guarantee the parts if you purchase them from their shop. Selecting the installation shop first, and asking them if they will guarantee the installation of parts that you bring with you could save you a lot of grief later. (you could save a few hundred dollars by purchasing parts from ebay if your local shop will allow that)
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Stuka
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Re: Dana 44 Cases

Post by Stuka »

Just to be clear, the housing is not the same across all FSJ versions of the D44. It did change over the years, and a 19 spline housing can't be converted over to a 30 spline.

As for used gears, I would never pay somebody to install used gears. The installation costs is higher than the parts cost (Unless you are going with lockers). A new Yukon R&P is something like 180 bucks last I checked.

I have personally installed used gears before, and they ran fine. They were quiet, and worked without issue. But, it took longer to get a proper pattern on them.
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Phils67
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Re: Dana 44 Cases

Post by Phils67 »

Correct me if i'm wrong but 70 and earlier were 19 spline closed knuckle, 71-73 was 30 spline closed knuckle, everything after were 30 spline open knuckle. Only reason i say this is because i have a closed knuckle front right now under my truck that was a 19 spline originally and i rebuilt it with a 30 spline locker and stock shafts from a 71, but it was originally a 19 spline housing
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Re: Dana 44 Cases

Post by tgreese »

I believe this is correct. Prior to roughly 1971, the front axle for the Wagoneer was the Dana 27, with closed knuckles and 19 splines. The closed-knuckle Dana 30 was introduced for the Wagoneer in 1971, and continued through 1973. This should have 30 splines. Starting in 1974, the Wagoneer got the Dana 44 open knuckle axle, also with 30 splines IIRC.

As I recall, a 30-spline version of the D27 was never offered for a Jeep vehicle, but was offered for some IHC vehicles. So they exist, but aren't common. It's interesting that the 30-spline axles from a Wagoneer D30 will fit in the D27 housing. AFAIK nothing else knuckle-in from a D30 axle will fit a D27.
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Phils67
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Re: Dana 44 Cases

Post by Phils67 »

I was specifically referring to the 44 fronts, sorry, i always tend to forget that wagoneers used the smaller fronts. Just speaking from my experience with early J truck fronts.
1967 Gladiator J2000, 1998 4.0L OBD2, T18, D20 twin sticks, D44HD/D60, Detroit lockers, 3.73s, 4wheel disc brake, FSSR, Dakota digital, etc.
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Stuka
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Re: Dana 44 Cases

Post by Stuka »

Ahh, I was speaking of the rear axle, not the fronts.
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Phils67
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Re: Dana 44 Cases

Post by Phils67 »

Yeah sorry about that. Coffee didnt kick in quick enough this morning when i posted that and my brain was in low range haha
1967 Gladiator J2000, 1998 4.0L OBD2, T18, D20 twin sticks, D44HD/D60, Detroit lockers, 3.73s, 4wheel disc brake, FSSR, Dakota digital, etc.
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