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Bad Day For My Dana 44

Discussion in 'Early CJ5 and CJ6 Tech' started by Michael Crabtree, Oct 16, 2020.

  1. Oct 16, 2020
    Michael Crabtree

    Michael Crabtree Member

    Lake County, CA
    Joined:
    Oct 5, 2020
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    42
    So, took the Jeep for a drive today. After bringing it home last month and crawling under and through it, I've been taking it on short little drives around the neighborhood to get a feel for how it drives and to try and identify any problems that might need to be addressed. Well, while on the way back home today, it started making noises while coasting. First just mild gear noises, but pretty soon it sounded like I was torturing a wounded yeti every time I let up on the throttle. Limping it home the last couple of miles as gingerly as possible, I finally made it back to the driveway where it gave a final "clunk". Looking underneath, the first obvious thing that stood out was that my rear driveline wasn't attached to the rear axle anymore. Cursing slightly, I crawled under and noticed that it wasn't a U-joint that failed, but the pinion nut itself had come loose and fallen off (seriously?). So other than the fact that this caused the pinion seal to come apart, I noticed an awful lot of play in the pinion shaft itself which definitely wasn't good.
    IMG_8536.jpg
    Bowing to the inevitable, I pulled the differential over off and had my suspicions confirmed. Loosing that nut caused the pinion gear to eat itself. Unfortunately I don't have the tools needed to rebuild this properly, so looks like it'll get towed to a shop.
    IMG_8537.jpg
    IMG_8538.jpg
    The question is, do I pay to have it rebuilt/replaced, or do I just go hunting for an entire new rear axle to throw under it?
     
  2. Oct 16, 2020
    Ohiowrangler

    Ohiowrangler Member 2023 Sponsor 2022 Sponsor

    Newark, Ohio
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    It can be saved, replacing will depend availability. Ron
     
  3. Oct 16, 2020
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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    you being in california
    I suspect you could find another axle to drop in
     
  4. Oct 16, 2020
    Lockman

    Lockman OK.....Now I Get It . 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Silver Hill,...
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    Dec 4, 2018
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    I've got a D44 open case..................if you decide to repair it yourself . Tools are a very good thing to invest in & often are fairly inexpensive.

    A lot of info & knowledge on this subject ,here ......... Plus, besides saving a ton of money , You'll have a lot of fun & experience if you do it yourself. :bananatool:
     
    Last edited: Oct 16, 2020
    Ol Fogie likes this.
  5. Oct 16, 2020
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    If you really cringe at someone else working on it, I’d hunt CL and marketplace first for a cheap drop-in replacement axle. Even if the ratios don’t match, just throw it in until you get the time/money/tools to fix yours. (If you go that route, and the ratios indeed don’t match, pull your front driveshaft so it doesn’t accidentally get put in 4wd.)
     
  6. Oct 16, 2020
    duffer

    duffer Rodent Power

    Bozeman, MT
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    Sep 17, 2009
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    Centered differential, 30 spline, 3.73? I'm guessing any axle from 72 through 75 will bolt in but Tim would be the authority on this.
     
    Lockman likes this.
  7. Oct 16, 2020
    Keys5a

    Keys5a Sponsor

    Florida Keys
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    Do you know what the axle is from? I see '57 M38a-1 which should have a 2-piece D44 w/ 5.38 gears, but then I see D30 up front, so all bets are off.
    -Donny
     
    Lockman likes this.
  8. Oct 16, 2020
    jpflat2a

    jpflat2a what's that noise?

    Hermosa, SD
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    Jul 30, 2003
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    Looks like a Trac Loc..centered flanged 44 would be my guess.
     
  9. Oct 16, 2020
    Michael Crabtree

    Michael Crabtree Member

    Lake County, CA
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    Oct 5, 2020
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    I believe they pulled both axles out of a mid 70s CJ5 since they have the 11 inch drums on them. So I’m guessing they’re 3.73s, but I didn’t see any markings or count the teeth, so not 100% sure.
     
    Lockman likes this.
  10. Oct 16, 2020
    Michael Crabtree

    Michael Crabtree Member

    Lake County, CA
    Joined:
    Oct 5, 2020
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    My wife actually cringed when I told her what happened today, but I actually enjoy the chance to get my hands into a differential, since I don’t have a lot of experience there. I’m very interested in learning more about them, but I’m just leery about screwing something up like not setting the pinion depth correctly and grenading another rear end...
     
  11. Oct 16, 2020
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    If you take your time and go by the book, they aren't hard to do right. A pair of setup bearings really helps things go faster.
     
    Lockman likes this.
  12. Oct 16, 2020
    73 cj5

    73 cj5 Not ready for the junkyard yet

    Clinton, Mississippi
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    X2 on the setup bearings. In a few hundred miles I'll know if I did mine right. Next time I regear I'll buy the pinion depth tool to cut down on all the guesswork.
     
    Lockman likes this.
  13. Oct 17, 2020
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
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    I have a d-44 19 spline that has been torn down, cleaned, and ready to be built. What d44 do you have?
     
  14. Oct 17, 2020
    Lockman

    Lockman OK.....Now I Get It . 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Silver Hill,...
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    Please turn your case 90 degrees & post another Pic. We are all just guessing without more........
    Oh Yeah.....IMHO, one can't " screw things up " any more than having a pinion nut unscrew itself ! That's just a fluke or somethin' missed by the PO. What are the TSM torque specs on those ? ......~ 200 Ft #'s , I believe . :shock:
     

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    Last edited: Oct 17, 2020
  15. Oct 17, 2020
    ralph zepp

    ralph zepp New Member

    Lousiana
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    Jan 31, 2020
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    Might call Holbrooks Speciality in Gladstone Or. They replaced/ rebuilt both the 44 and 27 limited slip units on my cj5. In the 1990's they kept complete differentials on the self. do not if they still do that. They have helped me with parts.
     
  16. Oct 17, 2020
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

    York, PA
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    If it's a centered diff and a Dana 18 transfer case.......that huge angle on the rear driveshaft created by this combination always scared me. I don't know if it would lead to this type of destruction or not though.
     
  17. Oct 17, 2020
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Hills of NH
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    That's the most unheard of thing I've ever heard of!
     
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  18. Oct 17, 2020
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
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    Sep 21, 2002
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    His signature says Dana 20.
     
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  19. Oct 17, 2020
    duffer

    duffer Rodent Power

    Bozeman, MT
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    Yep. Definitely a major screw-up by who ever put that together. It will take some effort to get all of the metal out of the pinion oil return if the housing is still good. That failure could have messed up the pinion bearing seats/bores.
     
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  20. Oct 17, 2020
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
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    I'll bet someone adjusted preload by how tight the nut was.
     
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