[Thunderstrike]

It's beginning to leak. Have wet spots of gear oil. Is this covered under the powertrain warranty?

If this something easy to do I would rather do it myself, so has anyone know of a link on how to replace this pinion seal on a Dana-44 rear axle? I checked out stu-offroad but couldn't find it.

[nfunlimited]

I had mine replaced on my '05 unlimited with the D44. It was under warranty. that was last summer. I think in my case dragging the axle through the mud may have forced dirt in to deteriorate the seal. Took the dealer no time to do it.

[Chris @ GATR]

It is a "basic" warranty item. However, for $10 and 45 minutes, you can do it yourself.

[Thunderstrike]

Originally Posted by Chris @ GATR

It is a "basic" warranty item. However, for $10 and 45 minutes, you can do it yourself.

Great, then -- I would rather do it myself.

[djt283]

Does anyone know of a write-up for how to change it? Mine is also leaking and I'm going to have to change it at some point too.

[Thunderstrike]

Here's a good write up I found.

http://www.universityofjeep.ca/pinion_seal.html

But, I'm confused about different procedures on the FSM which lists Rear Axle 194RBI or 216RBI instead of DANA 30 and 44.

194RBI procedure shows the need to measure the torque reading during removal, so the same torque amount can be set during install. It says to use an inch pound torque wrench. 216RBI procedure simply says use a spacer to tap in the seal.

I'm assuming 216RBI is dana30. I have Dana-44 so do I need to get the torque reading (follow the 194RBI axle procedure)?

Does anyone know which is Dana-44 -- 194RBI or 216RBI axle?

FSM says 194RBI axle has a collapsible spacer, but 216RBI axle does not have one.

[Thunderstrike]

PM reply from camper49. Very helpful so I thought I post it here for all to benefit. So, it means dana-30 and 44 do not have crush sleeve whereas dana-35 does.

Originally Posted by camper49

FSM shows that rear Axle 192RBI has it; axle 216RBI does not, so I don't know which Dana axle corresponds to two types in FSM.

192 mm=7.56 inches...a dana 35 ring gear is 7 9/16 inch diameter

216 mm=8.5 inches...dana 44 ring gear is 8.5 inch diameter

I think you can be fairly confident you have a spacer/shim type set up...the difficult part will be to turn that pinion nut loose while laying under your jeep...unless you have air tools...I don't.

I changed my front pinion seal as you saw in the pictures...I had the axle out so I could lean into the wrench to break the nut free.

before you loosen the nut...test the backlash feel by grabbing the yoke with your hand and dial it back and forth...it will go tap...tap...hardly any slop.

There's the nut with probably a washer underneath...then the yoke itself slides out...then there may be one or more washers/spacers under the yoke....just pull the yoke and leave any washers as they are....with the nut off, the pinion shaft will be real loose and sloppy...don't pull it out.

I took a small screwdriver and used a light hammer to tap the edges of the seal away from the neck of the pumpkin...you only have to bend it a little bit...it took a few minutes and you will ruin the old seal...but it will come out easy once you go around the circumference...remember which way the seal goes...there's probably a spring "garter" around the rubber...I can't remember which way it goes.

after you install a new seal and start threading the nut back on...it will be sloppy until you get close to the correct tightness...grab the yoke with your hand and dial it back and forth...it will go clunk...clunk...then tighten it a little bit...it will get better and better...go slow...don't overtighten or you'll crush the bearings.

remember I haven't done a dana 44 seal...I'm not qualified to instruct...so you can tell me how it goes....I wouldn't worry too much though.

[garthbrown]

One is the D35 and the other (without the crush sleeve) is the D44.

[Jerry Bransford]

Even if you have the D35c which has a crush sleeve, it'll be fine if you just retorque the pinion nut (use blue Locktite on the threads) to 160-180 ft-lbs after installing the pinion. That's the advice I got from Tom Wood when I still had my D35c and it worked fine for the several years until I sold that axle.

[LKrux]

im doin this job in a few days