post #1 of Old 09-03-2009, 08:22 PM Thread Starter
missionAvs
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D44 Swap Process

Hey guys so I just pulled the trigger on a D44 out of a TJ w/ tracloc and 3.73 gears . I have been searching for a little while now but have not found a write-up that explains the process step by step on a TJ. I read Stu Olsons install of a super 44 but he didn't really describe the install step by step. I am just wondering what order I should remove and reinstall bolts in (CA's, Trackbar, shocks etc...) Also can someone give me the run down on removing and reinstalling break lines? BTW My toolset includes four 6 ton jack stands, a capable floor jack, a few ratchet and wrench sets, and at least one buddy is coming over.
Thanks a bunch guys
BTW I have done several suspension lifts in which I have replaced the CA's and trackbar.


04 Willys Edition TJ Wrangler

Last edited by missionAvs; 09-03-2009 at 08:34 PM.
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post #2 of Old 09-03-2009, 09:30 PM
George Dickel
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It ain't rocket science. Take the old one out and put the new one in. You've got enough experience to knock this out quickly. Is this also a brake upgrade (drum to disc)? If so, you'll need new e-brake cables. Keep searching because I have gone as far as listing the part numbers on those cables here before...

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post #3 of Old 09-03-2009, 09:43 PM Thread Starter
missionAvs
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Quote:
Originally Posted by George Dickel View Post
It ain't rocket science. Take the old one out and put the new one in. You've got enough experience to knock this out quickly. Is this also a brake upgrade (drum to disc)? If so, you'll need new e-brake cables. Keep searching because I have gone as far as listing the part numbers on those cables here before...
I just wanted some reassurance I guess. Thanks for the reply, but just to answer your question, it is a drum brake set-up so I think all of the lines will just transfer over. Thanks for the reply!

04 Willys Edition TJ Wrangler
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post #4 of Old 09-03-2009, 09:50 PM
fishinjeeper
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Jeep Wrangler Dana 44 Swap from Jeep Cherokee

hope this helps

01 TJ. 35 inch KM2's. 4.5 RE. 2 inch body lift. dana 44. Detroit Locker. Olive Drab!! all set for trout and bambi!
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post #5 of Old 09-03-2009, 10:08 PM
hyperboarder
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It's easy, track bar gave me the biggest hassle. It'll probably take a couple hours.
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post #6 of Old 09-04-2009, 07:47 AM
rondak46
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I would not do it without 1/2" drive sockets and a torque wrench.
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post #7 of Old 09-04-2009, 10:19 AM Thread Starter
missionAvs
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Quote:
Originally Posted by rondak46 View Post
I would not do it without 1/2" drive sockets and a torque wrench.
Forgot to mention, but I have those as well. The thing I know least about is how to transfer brake lines over. The 44 comes with drum brakes and the e-brake cable attached.
Thanks for the help guys!

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post #8 of Old 09-04-2009, 11:09 AM
mikesbeachhut
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I installed a d-44 with no problems .Jack it up on 2 stands wheels off floor,take off wheels ,slide floor jack/wheels under diff pumpkin & jack up till it lifts the rear about an inch ,disconnect the drive shaft first,brake lines,emerg brake cables,lower shock bolts,lower trackbar bolt,sway arm links, axle side control arm bolts,. Just pull rear out put new rear in,connect back up in reverse fashion.I used a impact wrench to make it easy,if not use a big breaker bar & box wrenches.A word of advice-before you take things apart GO OVER EVER BOLT YOU HAVE TO TAKE OFF & MAKE SURE YOU CAN BREAK THEM LOOSE ,IF NOT RENT AN IMPACT WRENCH.
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post #9 of Old 09-04-2009, 11:13 AM
hyperboarder
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E-brake cables will annoy you, but will eventually give. As for the regular lines, you should be able to attach your stock hose to the distributor on the 44. You'll need to bleed the system afterwards.
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post #10 of Old 09-04-2009, 12:25 PM
reesemoe
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make sure you put up lots of pics

My Build

www.jeepforum.com/forum/f22/building-roxy-860189/
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post #11 of Old 09-04-2009, 01:12 PM
CCJ
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Quote:
Originally Posted by George Dickel View Post
It ain't rocket science. Take the old one out and put the new one in. You've got enough experience to knock this out quickly. Is this also a brake upgrade (drum to disc)? If so, you'll need new e-brake cables. Keep searching because I have gone as far as listing the part numbers on those cables here before...
LOL @this response.
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post #12 of Old 09-16-2009, 02:18 PM Thread Starter
missionAvs
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Ok so I've got the D44 in sitting in the garage ready for the swap. I had just one last question regarding the axle breather hose. Do you just pull it off the breather tube with pliers or is there another way to do it? Thanks for the help everyone, im probably going to do the swap this weekend or the next. I'll post pics here.

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post #13 of Old 09-16-2009, 02:31 PM
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Just pull it off.....

OlllllllO
Float Test Build
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post #14 of Old 09-16-2009, 02:54 PM
littledevilTJ
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yup, just yank it off, put it on the new axle with a hose clamp.
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post #15 of Old 09-16-2009, 02:54 PM
jazzman31
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Just jack it up far off the ground, your gonna need full axle droop. Put jackstands in front of the control arm mounts, and start taking stuff apart. It took me 3 hours to pop that crap 35 out and 3 hours to put the new 44 in. The track bar is the worst. But the new axle on the jack put the yoke in the middle of the ring part balance it and slowly jack into place, I put the upper control arms on first then the lowers then then springs and finally the track bar.

You have the tools, Just man up. Use your head and get after it.

I just recently done my this last weekend.
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