44HD Install and regear

[fr3db3ar]

This is my first attempt at a writeup so put it where you think it may belong.

Here's where it starts



Pull all of your cover bolts but the top one and pop the cover loose with a weapon of your choice..I use a deadblow hammer.


I had a leaky pinion seal too


I wondered why my pig got water inside and my antilock quit working....I found out why.


Here's the inside with stock gearing and center pin turned so you can see the center pin bolt that has to be removed to get the center pin out. You need a E8 torx for this and it's easier if you take off the passenger carrier bearing bolts first to allow straighter access.


For those who have never had your carrier out this is what a 44HD limited slip diff looks like disassembled.....except for that broken clutch plate...that's bad


Here's a closeup of one of the idle spider gears that was damaged by parts of the cluth floating around.


I didn't go into detail on extracting the carrier as that should be pretty self evident....take the 4 carrier bolts out and gently pry out the carier.
I also didn't go into detail on pulling the pinion. I used a pipe wrench to hold the yoke and a 1 5/16 socket to remove the pinion nut.. Changed the pinion seal and reassembled in reverse order with new bearings. I did add an extra shim under the pinion bearing to help make up for the difference in pinion gear size...it worked for me.

Here is the new pinion installed (4.10 gears...stock were 3.73) and the open carrier with the driver side part of the aussie installed along with center gear and c-clip cover. IMPORTANT.....ENSURE THAT YOU INSTALL YOUR STOCK THRUST WASHERS ON THE LOCKER FOR PROPER CLEARANCING. step by step photos You can also see the gear pattern from my gear install....It's not bad so I'll live with it....I set pinion preload to 19 in/lbs and backlash to .006" (first try )





Here is the carrier turned and ready for the center pin install


Dont forget to install the pins and springs per instructions with the kit


Slap some RTV sealant on the cover and put it back on


All comments are welcome. Hope this helps someone.

[nate]

19 in/lbs... is that what the book called for? I don't have a book in front of me, but that seems a bit high.

[2jeepsforus]

nice write up.... makes me not so scared to try mine, eventually

[kfab]

before you took the lsd out was it making a popping sound when you turned bc mine does

[dangerousdave]

the write up lacks a lot of info... sorry not trying to be a dick. by this i mostly mean about the install of the r&p. There are locker install guides on here so no biggie on that. Im just saying you left a lot of info on the install out. Like i said im not trying to be a dick.

[fpkites]

Also not trying to be a dick, but I wish you would have gone into it a little more step-by-step. I've seen a 44a torn down and reassembled (didn't do it myself), but I fear you may have instilled a bit too much confidence in somebody who hasn't done it before.

May I recommend listing the tools needed to measure backlash/preload? Perhaps some explanation of the use of said tools? What about a case spreader to pull the carrier? Pics of a few more steps than you have here would be extremely helpful.

[BigDaveZJ]

Good job guys. Way to harp on a guy's post that's 2 1/2 years old!!

[zj-monster]

Holy shit I love this website!!!

[kfab]

Ha no kidden me toooo

[fpkites]

Oops...I blame the noob....KFab's fault!

[OverkillZJ]

W...T....F...!!!

lol

[dangerousdave]

Oops...I blame the noob....KFab's fault!

agreed.

[naturalbornmudder]

It will give the guy a chance to update whether his R&P install held together...

[98ZJ5.9]

Also not trying to be a dick, but I wish you would have gone into it a little more step-by-step. I've seen a 44a torn down and reassembled (didn't do it myself), but I fear you may have instilled a bit too much confidence in somebody who hasn't done it before.

May I recommend listing the tools needed to measure backlash/preload? Perhaps some explanation of the use of said tools? What about a case spreader to pull the carrier? Pics of a few more steps than you have here would be extremely helpful.

I know for fact the jeep shop manual has a caution about the case spreader. I don't have it here But it basically cautions don't spread past x or the aluminum case will not return to its original dimensions. I've been told by two diff mechanics in two diff cities this can cause MAJOR problems!

Dave

[theksmith]

i know this is an old post, but did i miss something in the writeup or don't you have to use different shafts when you switch to the open style carrier.. or is that just a wj thing?

[Grandsrus]

Quadra-drive thing

[FrozenZJ]

Thought I'd post this here.

Here is a link to the dana service manual for this rearend. I used it when I did my 44HD.

http://www2.dana.com/pdf/X5001-CVSP.pdf

Things of interest would be the part numbers for the side shims (The JK ones would not fit. I tried) and the backlash is supposed to be between 4 to 6 thousands. Not the normal 6 to 10 thousands that a lot of dana axles use. I had to order shims as I had none behind the bearings from the factory and I had to move it a small bit. I also used a piece of metal bolted to te housing where the cover goes for a mount for my mag mount dial indicator.

anyway, fyi

[fr3db3ar]

Since this post is alive again.......yes....the install absolutely did hold together. I've never had a regear yet that didn't go well. I did eventually break a locker pin but Aussie replaced them, no problem. I've since gone back to open and sold the Aussie. Now I just need to pull the Ected out of the front and go back to open there.


Wheeling open diff is so much more fun.

[blackzj52]

^say what?
i hate my open diffs

[fr3db3ar]

Well then do I have a deal for you.

[SoCal ZJ 5.9]

Since this post is alive again.......yes....the install absolutely did hold together. I've never had a regear yet that didn't go well. I did eventually break a locker pin but Aussie replaced them, no problem. I've since gone back to open and sold the Aussie. Now I just need to pull the Ected out of the front and go back to open there.


Wheeling open diff is so much more fun.

Great information and update. Did you have any problem with the Ected in the front differential since they claim when unlocked it is basically limited slip, which it is my understanding is not recommended for front differentials?

[Bajad]

Love the color of the fluid....does anyone know if most or all Quadra Trac 249 installed ZJ's have the limited slip?

Baja-D

[fpkites]

Depends on what was equipped from the factory - I've never seen any percentages. My 44a was open before I slapped an Aussie in.

[quadratokn]

Is that 2 master install kits?