Dana 44 Rebuild: Pinion Depth, Backlash and Shim Setup

[@ovalwingnut]

Underneith, prone posistion, no head room and just flat out awkward access. I FEEL YOUR PAIN.

[@corybeckmann8823]

You have to load the differential carrier with 40 ish lbs of force (like prying it down with a pry bar) when you check gear pattern. It’s the extra resistance that makes the pinion and ring gear mesh together forcefully like normal load that leaves a consistent gear pattern on the paint.

[@vincentmamotos9937]

You gotta get a differential case spreader. It makes this portion a whole lot easier

[@CliffsHowTo]

I had one, but was trying to not use it, so I could return it. But I agree! That’s is the way to get it done!

[@ChrisLawley43]

I had a friend make me a case spreader an it’s almost the same as the OTC brand. I don’t know why so many use this method. I just started my build an these shims are paper thin.

[@vincentmamotos9937]

@@ChrisLawley43 are you asking why so many people use a case spreader method? or just shoving the shims method?

[@Longslyde1]

I've been modifying cars and trucks since I was 15. I'm 52 now. In all my time doing work on them, I would say body work, and gears are my biggest "HATES" of working on automobiles. I hate body work because it's a pain in the ass, but GEARS, .... omg they just pizz me off lol. I hate doing REPETITIVE work on pressed on chit because of a few thousands of an inch. Properly done, The Dana 44 should have the shims on the inside of the bearings because of the fooked up outer landings for the races on the carrier. But I get you doing it the way you did since it was thinker shims. Many won't be so lucky. Thin shims will never work there. I have all the tools, which for gears is a huge investment, and I still HATE it. I will say, the best thing ever engineered was the Ford 9". At least they had some foresight on how to make setting carrier backlash and preload up MUCH easier. Not to mention the fact you can actually pop the 3rd member out and work on it on the bench without removing the axle! Just rotate adjusters side to side, get proper backlash, and tighten for proper preload. Dana and GM just cheaped out with the frickin shims. You kept your cool better than I would have doing that install. That's why I don't you tube gear installs myself. The audio would be nothing but censored "Bleeps" LOL!

[@CliffsHowTo]

It wasn’t a good time, but I saved about $400 over what the shop wanted, and ended up with new tools. Also, the shop is a well known Jeep shop in the area, but only offered a 3 month warranty. I feel like even if you did it pretty not-right, it’d last at least 3 months. So no thanks! I’m glad I did it myself!

[@bingobandit]

So my 1998 Jeep Tj came with a Dana 44 and a lunch box locker. I want to replace the locker with stock gears as I don't offroad much and my locker is messes up. What's a good gearing?

[@twodogs9961]

Now I know why my local axle shop will only set up my axle out of the vehicle.

[@CliffsHowTo]

Yeah, not a great time, but I got it done!

[@brianbloom1799]

Use a small 1/4 Brass Rod, It wont damage it. as long as your Not slamming full force

[@randomrepair1680]

How did it turn out? No noise or problems ?

[@CliffsHowTo]

I’ve got about 2500 miles on it so far, and no issues!

[@stevevares8730]

Thanks! I’m doing my D44 in a 51 Ford F1 pickup right now. I’ve rebuilt engines and auto trans but never a diff. Had to source a new carrier and spiders for 19 spline drive shafts which aren’t as common. Fingers crossed haha

[@stevevares8730]

Thanks! I’m doing my D44 in a 51 Ford F1 pickup right now. I’ve rebuilt engines and auto trans but never a diff. Had to source a new carrier and spiders for 19 spline drive shafts which aren’t as common. Fingers crossed haha

[@stevevares8730]

Thanks! I’m doing my D44 in a 51 Ford F1 pickup right now. I’ve rebuilt engines and auto trans but never a diff. Had to source a new carrier and spiders for 19 spline drive shafts which aren’t as common. Fingers crossed haha

[@randomrepair1680]

Thanks!@@CliffsHowTo

[@bryanjordan7724]

How did you adjust the backlash?

[@CliffsHowTo]

Side to side movement of the differential using shims.

[@Rise-From-Your-Grave]

How many shims goes on each side?

[@CliffsHowTo]

You have to measure the backlash and pinion depth to make that determination. I show the prices in this video series. Check it out!

[@jimmyfreeze3782]

lol, video title makes it look instructional until he says "apparently this is the coast side and this is the drive side".

[@CliffsHowTo]

The first thing I say, in the first video in this series, is that this is my first time doing a differential. This series is me completing the job for the first time. I’ve put thousands of miles on this Jeep since then with zero issues, so I guess I did an okay job!