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Evolution of pimping a dana 44

Stomis

Stomis

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So Ive been doing a lot of reading. Mostly just speculative stuff about future upgrades for the trooper when its done and rolling (can never get too many steps ahead of yourself lol). It seems that within the past few years there are far more upgrades to the dana 44 to make it stronger. And these upgrades are addressing pushing weak points inward towards harder to fix areas.

Now I've always been the guy to say fullsize's over 35s should have a 60 front. But for someone with a rig like me a dana 60 is just way too huge of an axle for what the rig is. So what I've been looking into is building a very beefy dana 44 down the road, sorta as a dont need it but what to entertain my brain project.

Theres 2 things that have come out in the last couple years that have addressed two issues with beefing a dana 44. One of them is the ball joints and the other is pushing the weak point into the ring and pinion. Now that there are king pins to replace the ball joints and kits designed to install larger ring and pinions in the dana 44 housing couples with RCV shafts and reid knuckles the strength you can reach with a dana 44 seems crazy.

I was curious if anyone has played with these new upgrades? Especially the kits to fit JK 8.9in gears in low pinion dana 44s or dana 50 gears in high pinion 44s.
 
Seems like a high quality r/p would be better than .4" bigger

But I have no clue. I will be lurking though:)
 
Do you honestly believe that Izuzu would break a factory R/P? Or even a knuckle for that matter? I just dont see it having the torque, weight, or tire size to really stress that 44 to its max. Full sizes get away with a 44 and intelligent use of the throttle. I wouldnt think you would need to go gung ho on a 44 for the lightweight rig you have. I do have experience with the Reid knuckles, and they are solid for sure. If you break one you are doing it right, thats for sure. That being said, I am interested in what you come up with on doing it, I have never seen a kingpin swap. Got me curious.
 
Its not really about what I need exactly. Its more about the want to improve on things. Although one day I would love to pull the tubes out of a HP44 and make a pass side drop axle I don't see me doing that anytime soon.

The j4 kit puts jk Rubicon gears in the low pinion 44 case. That's a 8.9 in ring but thicker also and a pinion the size of a Dana 60. Factory torture tests put it at like 40% stronger than low pinion 44 gears.

As far as king pins go they are $200 a side. They say the original prototypes are still alive and well on the company owners jeep after DD and wheeling. They're also only $20 a side to rebuild.
 
if you're gunna spend the time to rebuild it and you don't need it for a DD the next Monday, go for it. You will have an audience and I'm sure a peanut gallery. :( I like the research you've done thus far.
 
K85 Octane said:
if you're gunna spend the time to rebuild it and you don't need it for a DD the next Monday, go for it. You will have an audience and I'm sure a peanut gallery. :( I like the research you've done thus far.
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Well Its already rebuilt totally fresh and shortened on the one side.
 
Fwiw, I have Reid knuckles, and they're beefy as hell.
I like em.

I hear good things about Bonefish Fab. kingpins.

Aside from that, I'm no help. :haha:
 
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This is something that tickles my fancy - I have a D44 on the front of my truck and would be interested to see what's out there for upgrades vs. swapping to a D60?
 
Would like to see what you do. I'll be lurking in the shadows as well. Lol. You can do a ton of upgrades and make the44 stronger than a stock 60. But it will cost a lot to do it. Would it be cheaper in the end to buy a pro rock 44 and already have the upgrades and good ground clearance?
 
Ive never looked into a crate axle before. $2600 with no outers, no shafts, no locker, no gears, just a housing with balljoints in it.

Roughly priced to build a custom axle.

$500 for reid knuckles
$400 for bonefish king pins
$300 for a jana 54 kit
$160 for dana 50 gears
$1400 for RCVs
$250 for 30 spline warn hubs
$900 for an ox locker and cover (could be cheaper for a detroit)
$400 for axle tubes if you use new
$200 for new wheel hubs and rotors

The only reused stuff in the axle would be the cast center section itself and caliper brackets.

Thats $4500. Not cheap but things like lockers and RCV shafts make it super expensive. I plan on putting RCVs and king pins in my current axle eventually. Im just no sure if Im going to build a new housing to switch to high pinion or not.
 
sokoloka said:
This is something that tickles my fancy - I have a D44 on the front of my truck and would be interested to see what's out there for upgrades vs. swapping to a D60?
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See thats my moral dilemma with the full size trucks. I like the dana 44 but the weight of a fullsize, especially some of the motor options in fullsize trucks makes that need for a dana 60 tenfold. Im not saying a 44 wont work or cant be built to work better, hell my trazer was 3/4 ton on 36s, but I just feel like when you break out of the 35in range regardless of upgrades you're pushing it on a dana 44.

I would love to see someone prove that wrong though. Maybe a dana 44 with a jana 54 ring and pinion kit and some RCVs along with some other work could make a reliable axle for a fullsize with 37s or even skinny 38s.
 
It would be interesting to see somebody build a D44 like this and then actually spend some time wheelin' it. The thing I always question is the cost to benefit factor as compared to just going with a D60.
 
6.2Blazer said:
It would be interesting to see somebody build a D44 like this and then actually spend some time wheelin' it. The thing I always question is the cost to benefit factor as compared to just going with a D60.
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Sometimes weight and vehicle size and tire size make dana 60s too much. I wouldnt want a dana 60 under my trooper with 37s...
 
Correct me if I am wrong, but could you also use a higher spline count diff, and have Yukon/RCD/Superior/ect cut you a set of custom axleshafts?

I have seen guys do that to the 10bolts, swapping a rear diff into the front and having yukon make them some. I know they was factory offered in 30 spline, like the rear, but its not as common as the 28 spline so less supported. Wonder if you could also do the 44 like that. I mean, that would be a pretty solid 44 after all that.
 
i had 4.10 gears in 2 dana 44 axles with 38" tsl swampers and old worn out 350 sbc . ripped the ring gear teath off each one.

then went to dana 60 with 4.10 and still going over 12 years later. :whistle:
 
454Sub said:
Correct me if I am wrong, but could you also use a higher spline count diff, and have Yukon/RCD/Superior/ect cut you a set of custom axleshafts?

I have seen guys do that to the 10bolts, swapping a rear diff into the front and having yukon make them some. I know they was factory offered in 30 spline, like the rear, but its not as common as the 28 spline so less supported. Wonder if you could also do the 44 like that. I mean, that would be a pretty solid 44 after all that.
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The problem I see with bigger splines at the diff is there really isnt much in the way of stub shaft upgrades. RCV offers 30 spline stubs and flanges but they are the same diameter as the factory 19 spline stuff.

And at $4500 to build the ultimate dana 44, your getting into custom 9" territory with real king pins and 60 sized axles. If you're dead set on keeping the 44 I could see it being beneficial to replace those parts with upgrades as they break but in an all out build there's no way I would drop that kind of coin and still have a dana 44.
 
454Sub said:
Correct me if I am wrong, but could you also use a higher spline count diff, and have Yukon/RCD/Superior/ect cut you a set of custom axleshafts?

I have seen guys do that to the 10bolts, swapping a rear diff into the front and having yukon make them some. I know they was factory offered in 30 spline, like the rear, but its not as common as the 28 spline so less supported. Wonder if you could also do the 44 like that. I mean, that would be a pretty solid 44 after all that.
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Well 30 spline 10 bolt stuff really isnt worth its weight. And IMO neither is keeping a 10 bolt. If you're going to stick to a half ton front you might as well get a dana 44 simply for more support in the market.

And yes its true the price it would take to bling a 44 is expensive. I dont think its quite 9/60 territory though. Dont forget you dont have to have RCV's. Theyre $1200-$1400. You could run chromos with good CTM or OX joints for $600-800.
 
Stomis said:
And yes its true the price it would take to bling a 44 is expensive. I dont think its quite 9/60 territory though. Dont forget you dont have to have RCV's. Theyre $1200-$1400. You could run chromos with good CTM or OX joints for $600-800.
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The CTM's alone are pushing $500, how do you get four chromoly shafts for ~$100-300?
 
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