will i need a shorter DS going from D35 to D44

fish4life · 07-25-2010, 05:46 PM

I all!
I would like to confirm whether i will need a shorter drive shaft when i swap my dana 35 to dana 44 (both TJ axles of course).

Supposedly, the dana 44 requires a DS that is 1" (or so) shorter. however my jeep does have 2.5" lift and so i would like to see what you all think.

(basically looking to see whether i need to spend $$$ on a new DS)

Thank you

**Benderff** · 07-25-2010, 06:13 PM

Probably not because you have a lift. The only way to know for sure is to get the axle under and see. (until then it's only a guess) The concern is if the axle is too long it could get pushed into the transfer case. You wouldn't want to order a new axle until you can measure the new set up anyway.

http://www.jeepforum.com/forum/f9/ho...e-swap-901419/

joules102 · 07-25-2010, 06:43 PM

I just replaced my 35 with a dana 44. It was very tight but I am running with the stock DS for now. TT and SYE are on the horizon when I get back to Wa state. Best thing to do is cycle it when you get the 44 in and have a look.

Curly5759 · 07-25-2010, 06:53 PM

I changed out my D35 for a D44, and the D44 is longer. The guy selling the axles had a driveshaft and Tcase with a SYE, so I bought it all. The original DS is so short, I didn't want to mess with trying to make it fit, or paying to have it modified.
I think you will find the original DS is to tight with the D44 and you will have Vibes. (I have a 2"BB)

Curly

fish4life · 07-25-2010, 07:57 PM

I did a search on this and some say yes, some say no for a new DS. Ultimately, it comes down to, why would Jeep supply two different length driveshafts if they didn't really have to? I'm thinking a 2" lift isn't enough to lengthen the distance between pinion yoke and TC yoke by much, according to the (a^2) + (b^2) = (c^2) formula, in which case the 1" extra DS length might be a problem.

I still have to see if the Dana 44 pinion really does protrude further inwards by 1" or not. That's just what i heard, but i haven't yet measured it myself. stay tuned lol.

**Benderff** · 07-25-2010, 08:54 PM

I did the swap not long ago. The pinion is about a inch longer. There is a thread on here that has pictures showing it is longer. If your driveshaft is to long just take it to a driveline shop and have it shortened. You don't need a whole new shaft.

fish4life · 07-25-2010, 10:20 PM

Quote:

Originally Posted by Benderff

I did the swap not long ago. The pinion is about a inch longer. There is a thread on here that has pictures showing it is longer. If your driveshaft is to long just take it to a driveline shop and have it shortened. You don't need a whole new shaft.

Update: I was talking to a buddy on the phone today about this and it turns out his buddy had exactly what i need .... a driveshaft from a TJ that at some point had a dana 44 rear end ... score. I picked it up just now and compared it to the D35 shaft. It is indeed an inch or so shorter.

Couple of new u-joints in this OEM spicer DS and I shall throw that in there when the axle sawp gets underway

fish4life · 08-23-2010, 07:55 PM

Ok, finished the swap a couple of weeks ago. Thought i'd update the rest on what went on.

With the dana 44 bolted in, the dana 35 driveshaft was almost impossible to get into the yoke. Once in, there definitely was not enough room left for me to run it and feel safe about the transfercase not being smacked. Even the rubber boot on the shaft was all squished in.

Definitely had to swap the drive shafts ... about 1" shorter or so.

Just an FYI for those that are interested.

djcrab · 08-24-2010, 11:06 AM

Thanks. Will be doing a 44 swap in a couple of months. Nice to know what I may have in store...

**Benderff** · 08-24-2010, 11:32 AM

Quote:

Originally Posted by djcrab

Thanks. Will be doing a 44 swap in a couple of months. Nice to know what I may have in store...

http://www.jeepforum.com/forum/f9/ho...e-swap-901419/