2004 TJ Dana 44 Differential Total rebuild - high quality parts advice needed - JeepForum.com

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post #1 of 5 Old 11-15-2009, 10:57 PM Thread Starter
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2004 TJ Dana 44 Differential Total rebuild - high quality parts advice needed

I am a jeep newbie. I bought a second hand TJ a couple of months ago which came with lots of modifications which were fitted a year ago. The rear diff has overheated and the crown and pinion as well as all the spider gears and bearings and seals need to be replaced. The crown and pinion are 4.56 and were fitted a year ago. I don't know the make but want to replace the worn parts with top quality replacements to try and avoid a repeat of this problem. I would like to get all of the parts from the same supplier if possible to keep the logistics of shipping them to the middle east simpler as well as ensuring consistency of manufacturing and warranties. I have found lots of information on crown and pinions but very little on the other components i need to buy. Can anyone offer any advice as to which manufacturer provides the best quality components (C&P, gears, bearings & seals)?

I currently have a LSD fitted (type not known) and am thinking of replacing it at this stage with an aussie locker but will need to replace the carrier to an "open" type...can anyone advise what I need to be looking for when it comes to ordering the new carrier and how I make sure that all the components ordered will fit together as one unit? IE Is it possible to get all the parts from the same manufacturer to ensure that they are machined to fit together?

I also need to replace the rear propshaft (driveshaft between SYE & Diff housing) as the double cardan joint at the front is shot. I don't know the make but I want to replace it with the best quality to avoid a repeat of the problem. I don't know the make of it but have attached some photos in the hope that someone will be able to recognise the make and model and let me know.

I would like to go for off the shelf items as it would be quicker to source as my car is off the road until I get it sorted out.

All and any help will be gratefully received.

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Propshaft 1.JPG   Propshaft 2.JPG   Propshaft 3.JPG   Propshaft 4.JPG   Propshaft 5.JPG  

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post #2 of 5 Old 11-16-2009, 05:23 AM
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Superior is a good source for axle parts. And yes, if you want to replace the LSD with a locker you will have to get a new carrier. I wouldn't replace the drive shaft, just get Spicer u-joints and CV assembly to rebuild the one you have. Hope that helps...

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post #3 of 5 Old 11-16-2009, 05:49 AM
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overheating is more common with low oil levels
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post #4 of 5 Old 11-16-2009, 08:51 AM Thread Starter
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Many thanks.
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post #5 of 5 Old 11-16-2009, 08:57 PM
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Are you sure that the prop shaft is buggered? Don't believe every thing that Shanfari tell you.


If you can't fix it with a hammer, you've got an electrical problem.
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