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Dana 44 rebuild; Dana 44 rear axle rebuild
Topic Started: Dec 5 2016, 08:29 PM (1,050 Views)
Charlie
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Thought I'd post about the rebuild of the Dana 44 rear axle in my 1964 CJ3B.
Since I want to go through the entire axle, I decided to remove it from the jeep.

Found this hub puller on e-bay for $30.
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Works great! Axle seals have been leaking for a while, what a mess!
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Found this holder that attaches to my engine stand, makes it much easier to work on the axle. Getting crowded in the shop, two CJ3B's, an M38, an M100, a T3C and a M274A2! I need to find more storage room!
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Everything is apart, now for a lot of cleaning and inspecting to see what I can salvage. The "clunk" I was hearing was the pinion moving in and put!
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More to follow.
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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oldtime
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Very nice attachment for the engine stand.
Never seen one of those before.

By the way that's a Dana 44 and not a model 41 so I changed the title.

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Charlie
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Thanks. What is the difference between a 41 and a 44 and how do you tell them apart?
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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oldtime
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The Dana 41 rear axle assembly began production in 1946 into 1951.
The D41 never changed during that timeline.
The Dana 44 rear axle assembly began production in 1951 and was used by Jeep prior to 1976.
The D44 was upgraded several times from 1951 through 1975.
Most parts were interchangable with the D41 axle assembly until late 1956 when the first D44 upgrade occurred.
Even a few of the latest CJ 1975 D44 parts will interchange with the D41.

To fully understand the D41 and D44 axle it would be wise to study the Jeep CJ from 1941 military beginnings through end of the CJ era circa 1985.

More specifically it would be helpful to study Jeep Military and CJ Rear Axle Progression.

Knowing the physical differences between axles only entails a part of that knowledge.
Understanding the reasons for the various changes promotes a more complete appreciation of the changes.

IMHO, Not all changes occurring throughout the CJ era should be defined as progress.

Generally a good look at the carrier cover will readily define the specific Dana axle model.

Sorry if I have not really answered your question as It might take a really long text to convey a meaningful understanding.

See:http://z4.invisionfree.com/CJ3B_Bulletin_B...?showtopic=3026

or search: Dana 41 44

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Charlie
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Came across this rebuild thread, lots of information on setting pinion pre-load, pinion depth, backlash and tooth contact pattern:Dana 44 Pictorial Build
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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The weather has been pretty bad, but today it warmed up and I was able to clean parts and paint. The brakes are built and ready to go. I am going to use a speedi-sleeve to repair the yoke. I did find "44" on the axle housing after I cleaned it up.
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1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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I've got everything apart, cleaned, the parts have arrived, and I'm ready to start the process of setting the pinion depth and pre-load. During the tear down, I found two shims on the pinion shaft between the inner end of the yoke and the oil slinger. These shims are slightly smaller than the ones that go under the outer pinion bearing. I don't see these shims on any of the parts diagrams that I have found, and I don't see any purpose for them, unless somebody was trying to move the yoke further out, possibly to reposition the seal wear surface. The yoke did have a pretty deep wear groove and was obviously leaking badly, but the yoke has now been repaired with a speedi-sleeve and will be reused. I don't plan to reinstall these two shims unless somebody more experienced than I thinks there is a good reason to. Thanks!
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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Starting the assembly. Pinion pre-load is 9-10 in. lbs. Backlash is .009". Tooth contact pattern test is next.

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1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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Had to tear everything back down. When I installed the axles, I realized that the axle gears, spider gears, shafts and shims had a lot of wear. M'o money!
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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I purchased a new spider gear set. Everything seemed to fit, but the gears would only turn about 1/2 turn before they locked up. I removed and reinstalled them several times, but it was always the same. I put the old gears back in and they turned fine. It appears that there is a machining error on the new gears, so the seller has agreed to take them back and refund my money. At this point, I think I will just reuse my old gears, at least I know there is nothing broken, just some wear.

Now I'm waiting for it to warm back up and stop raining so I can put it back together.
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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Found an NOS kit for Dana 44 thrust washers and cross shaft. Installed with my old gears and it seems to have corrected the loose motion in the spider gears. Carrier is back in the housing, 9 in. lbs pre load, .007" back lash. Tooth pattern is next.

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1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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This rebuild is finally finished! So far, everything seems to be working fine.
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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Charlie
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I had issues with the speedi-sleeve on the yoke, tore back down and re-shimmed the pinion for correct preload, installed a new yoke and pinion seal. I am much happier this time around.
1964 CJ3B
1952 M38 w/M100
M274A2
NE Alabama
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