Question

[ChiefMike]

Anybody near Ft Belvoir have any experience with DANA 44's? I think I may have a bit of a problem...not sure though.

http://i18.photobucket.com/albums/b111/Jeep_Geek/Jeep%20Picts/BadPinion.jpg

Seriously though...I wanna replace/repair this puppy. Looking for a DANA 44 with a 3.73. I will not replace this with another open diff. I can get a new ring and pinion gear from 4WD.COM for $163. But if I can use this casualty to improve it I will. However, I wanna do the work and learn how to do this if at all possible.

:-)
Mike

[miljeep]

I thought I saw an 8.8 for sale in MD on MJ somewhere.

[ChiefMike]

Yeah...I saw it on Craigslist I believe....that would be a good alternative, huh?

[94GC52]

Yes an 8.8 would be an upgrade. The only issues with doing a gear set your self is having ALL of the right tools. This isnt something you can do with a hammer and pliers. Other than that its just ensuring that you have the proper clearances set and adjusting the gears so that you dont bind. I did a dana 35 gear replacement on my old YJ it wasn't too hard just took more ime than i had planned on.

[ChiefMike]

I agree. Idealy what I would LIKE to find a DANA 44 with a LSD and just swap axles. I know I can get a new pinion and ring gear for about $170 from 4WD but I also know I am am in over my head on replacing those let alone putting a limited slip diff in on my own. I know my limits and that is well outside of my ability.

[94GC52]

I agree. Idealy what I would LIKE to find a DANA 44 with a LSD and just swap axles. I know I can get a new pinion and ring gear for about $170 from 4WD but I also know I am am in over my head on replacing those let alone putting a limited slip diff in on my own. I know my limits and that is well outside of my ability.

An axle swap is going to be just as much work as the gear swap. Granted you not worried about proper tolerances and such, but its still a project.

[crazy4ink]

By the looks of the pic, your pinion bearing failed and allowed the pinion to walk too close to the ring gear. You could also have a carrier bearing that went out and allowed the carrier ro shift inside of the housing. A Master install kit and a new ring and pinion would have you back on the road quicker than an axle swap.

[ChiefMike]

Right now the Jeep is at Cottman's Transmisions in Alexandria. Jeff is gonna look at it and give me a damage assesment and I'll go from there. I know I couldn't find the chunks in the pumpkin which makes me believe it's been this way for a while. Those 2 sheared teeth are not just worn down. The third has obviously been damaged by the other pieces floating around...but I didn't see any damage to the other teeth....makes me wonder.