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Unread 10-29-2009, 10:55 AM   #1
willydigger
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Dana 35 to Dana44 Swap

Will a Dana 44 from a 02 TJ bolt in directly with an 05 TJ? Are there any differences with the yoke or drive shaft that need to be considered?

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Unread 10-29-2009, 11:06 AM   #2
drummerchukb1
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from what ive read, it should be a direct swap. im about to swap a d44 from a 2000 into my 98 once i get it re-geared
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Unread 10-29-2009, 11:13 AM   #3
rideraa
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I'm about to do one also, watch your drive shaft length, info I have found says it needs to be a bit shorter (like as little as a 1/4" reported by some, if thats true it could break the "T" case under compression) also was stated a moderate lift would accomodate the difference ... For Rudi 44 you will also need a 1310/1330 u joint and different cables for the parking brake (rear disc)
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Unread 10-29-2009, 12:08 PM   #4
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Quote:
Originally Posted by rideraa View Post
I'm about to do one also, watch your drive shaft length, info I have found says it needs to be a bit shorter (like as little as a 1/4" reported by some, if thats true it could break the "T" case under compression) also was stated a moderate lift would accomodate the difference ... For Rudi 44 you will also need a 1310/1330 u joint and different cables for the parking brake (rear disc)
It's not from a Rubicon. What is considered a moderate lift? I have a 2inch suspension with 1inch BL/MML.
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Unread 10-29-2009, 12:28 PM   #5
Benderff
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Yes it is a direct swap. I'm guessing it has drum brakes, but if it has disk you would need new parking brake cables. The pinion is a little longer, but with your lift you should be fine. Once you get it under your jeep just make sure the driveshaft has enough play that it will not be pushed into you transfercase.

Here is what I just built. It's going under in next week.
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Unread 10-29-2009, 12:37 PM   #6
rideraa
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your going to have to use your own judgement on the shaft length ... can't help you there ... did you extend your bump stops with the lift ... that maybe some insurance ...

report back .. I'd be interested in your findings .. as of now the soonest i will be installing is Nov 4 ... and that will be with a 4" lift ...

sorry i can't be any more specific ... person above ... says ok....
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Unread 10-29-2009, 01:38 PM   #7
bean66
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I just did this swap about 6 weeks ago. Yes it is a direct bolt up swap for most of the components.

However if its a RUBI D44 then the snout is a bit longer and it has a 1330 yoke output. You have a few choices here to mount this up,
A. get a 1310/1330 combo u-joint.
B. Have a 1330 yoke welded onto your drive shaft and install a 1330 u-joint. Most drive shops can do this and the yoke only costs another $20 or so.

Some issues i ran into:
1. Disk brake cables vs the stock cables from the drums.
2. Speedo gear change. They are pretty pricey at $80.
3. Vibes, since the snout is longer this increases the shaft angle.
4. Bad bearings in the axle as well as leaking seals.
5. Pump installation and purchase for rubi lockers.

This has led me into, TT, SS SYE and a new DC driveshaft, adjustable control arms.
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Unread 10-29-2009, 01:43 PM   #8
willydigger
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Are there any vibes or driveline problems with a non-Rubi dana44 due to the longer pinion? How much longer is the pinion?
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Unread 10-29-2009, 01:50 PM   #9
theducksguts
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For non rubicon TJ Dana 44's it isn't more than an inch longer. With your lift you should be fine. Just compress the suspension and make sure the slip joint does not contact the Transfer Case. It is not expensive to have a D35 TJ drive shaft cut down and shortened.
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Unread 11-15-2009, 10:48 PM   #10
bmxrules39
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I want to re-open this thread to say that I was wondering about pinion length because I'm about to do this swap (97 D44 into my 97 D35), I just a super short shaft kit with a TW driveshaft, I have no t-case drop and a 4.5in lift. So I'm thinking I'll be fine to do it, but just wondering..
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Unread 11-15-2009, 10:54 PM   #11
Benderff
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I did a tummy tuck at the sametime as my axle swap. If I had not done the tuck I would have needed to cut the drive shaft down.
I am on 3.5'' of spring lift and the belly up raised the transfer case output 2 inches. I also have a SYE with a Tom Woods shaft that was cut to size for the lift. I think you will just have to get the axle under the jeep and see.
Here is my write-up vvvvvvvv
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Unread 08-30-2010, 06:04 PM   #12
willydigger
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Just a quick bump. I installed the Dana44. It took a full 8 hours with several hiccups along the way. Mostly my fault. The biggest problem was a few broken bolts due to an over aggressive impact.

Here are some pics of my drive shaft. This first image is will the Dana35.




Here is the drive shaft after with the Dana44.




Now that I look at it, I think I have a leaking axle seal. Crap!
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Unread 08-30-2010, 06:14 PM   #13
Benderff
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You know you need to have the drive shaft shortened right?

With the seal leak; did you use any sealer around the outside of the axle seal? Did you have the axle shafts pressed apart,and does the new axle have disc brakes??
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Unread 08-30-2010, 06:34 PM   #14
wushaw
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[QUOTE]You know you need to have the drive shaft shortened right?[QUOTE]

X2
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Unread 08-30-2010, 07:31 PM   #15
willydigger
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Yeah I know. The pic is for others thinking of doing the swap.
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