2003 TJ Dana 44 - JeepForum.com
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post #1 of 11 Old 03-17-2019, 07:29 AM Thread Starter
tpmx
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2003 TJ Dana 44

Hello All,
I havent been on here for awhile but need some help from you guys that always provide the best advice.
I just purchased a 2003 TJ with a salvage title,the jeep is from North Carolina and has zero rust.
The jeep is a 4.0 5spd with some aftermarket parts.
The big issue is the rear Dana 44 left axle tube is bent about 3/16 of an inch,
The unit has an electric locker in it now but I havent checked yet to see what gears may be in it.
What I would like pointed in the right direction on is it possible or even worthwhile maybe getting the axle tube straightened
or would you just maybe part out the axle and go to another one.
I have a Ford 8.8 out of an explorer that I was going to put in my Y.J but sold the YJ recently instead
The 8.8 is 3:73 gears disc brakes
I was thinking just putting it in this TJ but would really like to use the electric locker and stay with the 44
Whats your thoughts?
Thanks in advance

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post #2 of 11 Old 03-17-2019, 08:36 AM
Ironhead
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if the bend is in the tube, it can be cut out and sleeved with minimal expense.

i guess it depends how much damage was done


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post #3 of 11 Old 03-17-2019, 08:43 AM
biffgnar
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Axle tubes can definitely be straightened. I'd try that all day long before swapping that axle for an 8.8.
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post #4 of 11 Old 03-18-2019, 09:58 AM
Jerry Bransford
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Quote:
Originally Posted by biffgnar View Post
Axle tubes can definitely be straightened. I'd try that all day long before swapping that axle for an 8.8.
X2.

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post #5 of 11 Old 03-18-2019, 05:26 PM Thread Starter
tpmx
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Thanks for the responses
Thats what I am going to do,going to start taking it out tomorrow after work
Suppose to start warming up here
I feel I have nothing to lose
going to give it a try
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post #6 of 11 Old 03-19-2019, 05:21 PM Thread Starter
tpmx
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Dana 44

I started on the TJ tonite.
First thing I started doing was measuring to see just what is going on
I jacked the jeep up and put heavy stands under the frame on each side
I took off the rear wheels and leveled the rear axle with the wheel well openings in the body on each side
I measured from the top of the brake drums up to the body opening and jacked the axle around until I got each side the same
Then if I measure from the brake drum up to the center of the trailing arm bolt I get 5/8 inch different
Shorter on the driver side
Then if I lay a straight edge on the back side of the drivers side axle housing tube It looks to be bent forward about 1/8-3/16 inch
I realize this isnt the best way to measure anything but figured it would give me some idea of whats going on
My question is do you think an 1/8 or so would amount to be 5/8 inch out at the drum?
Not sure of a better way to check anything but I guess when it comes down to it I just need to drop the axle and strip it down except for the pinion and see what I can do as far as straightening it
I have a nice piece of heavy I-beam,some jack stands chain and 20 ton bottle jack and see what I can do
I f I need to ican machine some bushings and sleeves and get a piece of straight shaft to check the alignment
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post #7 of 11 Old 03-22-2019, 09:45 AM
j_bydesign
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use a laser and a ruler on either side... square up the laser across the bottom of side and then measure the difference on the other side... this takes any suspension quarks out of the equation


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post #8 of 11 Old 03-22-2019, 06:28 PM Thread Starter
tpmx
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I started making a truing bar and bushings today
I ordered a length of TGP 1.500 stock long enough to reach thru the axle tube from outer seal to outer seal plus a
few more inches and machined the two center bushings,still need to make my two outer bushings and then get the rear axle out and tore down
so I can see about getting it straight
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post #9 of 11 Old 03-31-2019, 04:03 PM Thread Starter
tpmx
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Worked on the Dana44 a little this weekend
Getting it pretty close but still have a little tweaking to do
I get one side good and then the other side will be off a little
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post #10 of 11 Old 03-31-2019, 04:47 PM Thread Starter
tpmx
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Heres my setup
Nothing fancy but its working
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post #11 of 11 Old 03-31-2019, 04:50 PM Thread Starter
tpmx
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not sure why it rotates my images sometimes
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