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post #1 of (permalink) Old 12-19-2002, 03:20 PM Thread Starter
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front tj dana 44 progress

I have been working on building this axle for about 6 months.... the real delay is the fact that I'm really cheap and I have to wait on my dad to do the machine work (for free). so far I have $150 into this axle and I only have to cut down 1 axle shaft.
heres what has happened so far:
1. I bought a high pinion d-44 housing for $50
2. I had the tubes cut off at the housing and the housing bored out on a horizontal mill to the outside diameter of a tj d-30
3. I pressed the tubes out of a tj d-30 I got from a "put this in for me and keep the old one" deal.
4. I ground the inner knuckles off the d-30 tubes..more on this later
5. I had to cut 2 3/4" off the long side d-30 tube. i figure that must be because of the width difference between the d-30 and d-44 housing.
6. I pressed the tubes into the housing, set the angles, set the width, checked spring perches and welded it tight.
7. I torched the tj inner knuckle apartand welded the part that holds the ball joint to the axle housing for the upper control arm mount. this involved LOTS of measuring and patience with the angle finder as this mount has several angles to it.
then I painted the whole works so it wouldnt rust... I dont wanna hear about the color.. its all I had..
it looks like this now.
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post #2 of (permalink) Old 12-19-2002, 03:25 PM Thread Starter
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Re: front tj dana 44 progress

heres another pic of the mount on the housing. as it happened, shock mounts fit perfectly in the ball joint hole.

next I have the following thinds to do
1. get the inner d-44 knuckles bored out like the housing.... waiting for those now.
2. aquire some flat top knuckles [img]images/graemlins/ooo.gif[/img]
3. I have the spindles and hubs. this axle will be 5 on 5.5 bolt pattern. [img]images/graemlins/cool.gif[/img]
4. I need to buy an ARB and reverse cut 4.56's.. [img]images/graemlins/frown.gif[/img]
5. I need new bearings, seals etc.

the goal is to get a 5 on 5.5 front d-44 with locking hubs. I bought the spindles and hubs for $100 from a board member so I'm at about $150 so far... I hope to eventually sell the d-30 she has now with the ARB and 4.56's to pay for most of the swap.
it might be ahwile yet though, as I have more time than $$$$$!
one other thing...
no booger weld comments..this really isnt one of my finer examples of welding...but it is a good strong weld
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post #3 of (permalink) Old 12-19-2002, 07:39 PM
 
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Re: front tj dana 44 progress

I put a Dana 44 out of a Wagoneer into my TJ. Worked great and didnt have a lot of money in it considering I put 4.88's and a detroit soft locker in it with warn premium hubs. So far so good. The original steering for a Wagoneer works just fine and does not have any clearance issues. I would suggest it to anyone who wants to upgrade from the dana 30 and get manual hubs.

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post #4 of (permalink) Old 12-19-2002, 10:06 PM
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Re: front tj dana 44 progress

Is that thing painted <font color="#006600">green</font color> or is it just a trick of the light?
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post #5 of (permalink) Old 12-20-2002, 02:38 AM
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Re: front tj dana 44 progress

yeah i think its green because anything green on a jeep adds 50 horsepower.. duh! HAHA
post #6 of (permalink) Old 12-20-2002, 05:46 AM
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Re: front tj dana 44 progress

That thing looks good. I can't wait to start on my D44 front. Shouldn't be long now.
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