Great Lakes 4x4. The largest offroad forum in the Midwest - View Single Post - Dana 44- thick or thin? Master instal kit required?
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Old February 15th, 2007, 10:20 AM   #4
Jeeperz Creeperz
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Originally Posted by FrankNBrew View Post
I've been shopping for gears lately, and I have a couple questions.

1. Why are there thick and regular ring gears for Dana 44s? What applications would require a thick gear?
Regular gears are used with the correct carrier. Dana 44 axles require a different carrier for different gear ratios to position the ring gear in the correct area. Ratios 3.07 to 3.73 require one carrier and 3.92 to 5.89 require another. The Rubicon Dana 44 uses a 3.73 ratio carrier with a thick ring gear to position the gear in the correct area (Rubicons have 4.10 gears and should use the 3.92 to 5.89 carrier but instead use the 3.07 to 3.73 carrier)

On the Rubicon, you can get 4.56, 4.88, and 5.13 thick ring gears. To go higher than 5.13 you will lose the factory air locker.

Originally Posted by FrankNBrew View Post
2. Is a master install kit necessary for regearing? My TJ has only 17,000 miles on it. I doubt the bearings are worn out.
I would say yes because most of the time you will destroy the inner pinion bearing when you remove it. Also, since the Dana 44 is shimmed under the bearings (and outside the race, depending on year) it is often necessary to reshim the carrier to get the correct backlash and you'll have to pull the carrier bearings off to do this.

Originally Posted by FrankNBrew View Post
3. Where can I find detailed instructions for regearing a D30 and a D44?
That's a good question. None of the gear manufacturers I'm aware of have a specific write-up for either axle, they're all a general overview of how to do it. The only place I can think offhand that would have it would be the shop manual for your vehicle.
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