chewed up dana 44 front

[barrolde]

Was not happy to pull my front diff cover and see this! I was almost done all the work I had planned too.

Obvious question is - is this normal wear and tear or abuse or a bad setup? The fluid was dirty but not low. I'd like to determine a potential cause so I know how to proceed, i dont want to just put another dana 44 in there if something is wrong w/ the setup and this will only happen again.

This is an open knuckle dana 44 right? but I'm not sure of the gearing yet, will count now. It is 4.10 on the 14 bolt cop rear diff.

Its passenger drop from my np205 and is turning 37" procomp's

The knuckle on the driver side axle reads 4358, the inner axle says spicer. The main diff gear reads 1 23 79 dana d 18520 b3r19 05-11

I guess I need to completely figure out what I have and then what to do... any suggestions?

[69CSTDawg]

assuming its probably 4.10 or 4.11 in the front or else one axle would try to pull the other

[barrolde]

Thats what I was thinking too.

Forgot to mention, the possible cause I could think of would be it jumping into 4wd unintentionally?

The floor shifter of my np205 is loose and rattles so i very gently put tension on it w/ a bungee cord so it stays back in 2wd high. Maybe there is too much tension on it and it p pull it into 4wd over bumps or something causeing the diff to engage at higher speeds than it should?? It shouldn't be able to do that unless I have my manual hubs locked in though should it?? I never do unless i'm using 4x4

cheers!

[modblacksmith]

Even if it did pop into gear at high speed you'd hear it in the transfer case too. The damage that you have looks more like something done 4wheelin. I would just replace the carrier and the gears. You mite also check the bearings and races to make sure they aren't chewed up.
Dana 44's are good axles to run, yes there not the strongest out there but for street use and light to moderate wheeling they will hold up just fine.

[barrolde]

Mr. blacksmith... my hero!

I'll go find a d44 and do just that, should not be hard w/ the info available here.

Last question, this appears to be an open knuckle diff right? I was actually hoping it was closed so i could switch to open because the turning radius on the beast is horrible.

[barrolde]

The top and the front inside of the pumpkin are scored from the gear destruction... am i ok to still use those parts as long as i put fresh gears in?

i would think yes but want to be sure

[Altec]

I do believe you have 4.11 gears based upon these numbers: "1 23 79." It is most likely a 37:9.

That breakage looks to be from improper setup.

You have the the more desirable 44. It has a passenger flat top knuckle. Popular in the off road scene for crossover steering conversions. I'm gonna assume the axle was changed? Since in '78 GM stopped using flat top knuckles, and I'm not 100% on this but I believe '80 was the last year for the Dana 44 in the front.

I'd rebuild it myself. Good time to change your gears, and you can set it up so you know it is done right.

Edit,

Oh, the 205 issue is caused by warn shift rails. I'll see if I can find some repair info for you.

[trixter99]

every one says that these 44s are so strong but I shredded a couple of these diffs and lost faith in them. So I went with a I ton front and rear diffs.

[Altec]

Originally Posted by trixter99

every one says that these 44s are so strong but I shredded a couple of these diffs and lost faith in them. So I went with a I ton front and rear diffs.

Like anything, they have a application. A full size, with large tires only lasts as long as you allow it. For a street truck you can go up to about a 39" tire. If you have a mild trail/farm truck I wouldn't go over 37". For a hard trail rig, 35".

Just remember, a Rockwell can be broken if the driver doesn't know what they are doing.

I like the 10-bolts...

[special-K]

I've run 37s on quite a few Dana44 trucks. I have broken axles,they were wheeled with no mercy. But,I never had a differential problem. I have run Tru-Tracs in some,too. When the axles broke it was due to worn out axle u-joints,spindle bearings,and once when escaping a quarry by way of alternate route when the cops showed up and blocked the entrance. I had to climb a huge and steep bank to the road. The tires were spinning hard when one tire hit the pavement and the other was in mud. That'll do in most any axle. I have broken 2.5t Rockwells,too.

[thinair]

I've ran 33s to 44s,including boggers on a HD dana 44(which really no difference but the lockout)......and as stated above, wheeled hard at times and maybe broke some axle shaft joints. Went into the garage and grabbed another one, didn't have to hunt/find one or pay too much money for it. And yes......they all break

[barrolde]

Wow guys, thanks for all the input! The truck is going to be mainly a street queen and partially a wheeler so in the interest of time, money and science I will keep the D44 front for now and swap out the gears.

HOWEVER - I do worry about improper setup.. could the angle of my front drive shaft be so off that its causing premature wear?

I've got go grab a coffee but will climb back under and rescour for all possible id #'s and take another couple pics. As long as nothing stands out as terribly wrong from that, i'll leave as is.. maybe it was just wheeled hard, I did not get much on the history of the truck when I got it.

cheers!

[barrolde]

Ok.. here is what I know.

Upper diff housing reads 2C36586
Lower diff housing reads 445CF - this indicates dana 44 and its a 10 bolt, good.
Inside of diff cover reads 0E0902
Main gear reads 1 23 79 dana d 18520 b3r19 05-11 - I counted 45 teeth on this gear so 4.09 is right to match the rear gearing.
The knuckle of the drivers side axle read A3R4
Knuckle on the pass side reads A358

They are 6 inner bolts on the manual locking hubs and 8 outer bolts. Google doesn't tell me anything about those axle #'s, hoping someone here can shed some light on this setup and whether its suitable for the d44 thats in there.

Altec if you are still around, how do I tell if a crossover steering conversion has been done yet? I'm slow, but learning!

[1969K10]

standard steering, the steering box turns the driverside wheel, and a connecting rod turns the passenger side wheel

cross over steering, the steering box turns the passanger side wheel, and a connecting rod turns the driver side wheel.

from what i see in your pictures, you do not have a cross over set up.

[barrolde]

Hi 1969K10, thanks for confirming that. You are right and from what I have read, I dont need that (yet) anyways

Anyone see anything wrong w/ the front drive / axle / diff setup from the pics that would have caused the wear or reckon its just from hardwheeling? Trying to pull another truck out of the mud maybe?

[88bagedntaged]

Originally Posted by barrolde

Hi 1969K10, thanks for confirming that. You are right and from what I have read, I dont need that (yet) anyways

Anyone see anything wrong w/ the front drive / axle / diff setup from the pics that would have caused the wear or reckon its just from hardwheeling? Trying to pull another truck out of the mud maybe?

Well Sir, First off hello !! I can tell you for what I have the dana 44 has done more than its share and has not givin up on me. I don't see anything that would be the cause in the pics but it's always hard to tell anything in pictures. But don't give up on the smal but tough Dana 44 I have a 454 turbo 400 running mine on 33x12.50's and I'm currently installing a doubler t-case set up

[special-K]

That angle doesn't look bad to me at all. That wouldn't affect what's going on inside the housing anyway. Everything inside is "fixed" in position and nothing that occurs outside has any affect on it. The set-up refers to the lash,play,tolerances between moving parts. It affects how the gears mesh/engage. Too much slop is bad and so is too snug. If a carrier or pinion bearing is badly worn it can cause slop that breaks parts. Usually that is ring & pinion,though. I would disassemble and clean everything. I can't see too well in the pictures just exactly what parts are affected and in what way.

[propanemudtruck]

Originally Posted by special-K

I've run 37s on quite a few Dana44 trucks. I have broken axles,they were wheeled with no mercy. But,I never had a differential problem. I have run Tru-Tracs in some,too. When the axles broke it was due to worn out axle u-joints,spindle bearings,and once when escaping a quarry by way of alternate route when the cops showed up and blocked the entrance. I had to climb a huge and steep bank to the road. The tires were spinning hard when one tire hit the pavement and the other was in mud. That'll do in most any axle. I have broken 2.5t Rockwells,too.

Not to HiJack this thread, but I'd sure love to hear the rest of this story! Well the beginning of it would be nice too!

['63GENIII]

I've actually had a ring gear bolt go through the r&p on a 72 Blazer and it looked very similar to the damage you're showing. The bolt got wedged into the ring and knocked half of a couple teeth off the pinion. I was camping way out there (closest parts were 70+ miles) so I had to drain the diff into my only water jug, beat the bolt out of the ring gear, seal the broken gasket on the diff and refill. I drove that truck like that for another 3 years. Just lucky I guess. I would think you could swap the whole axle for less than the install on a new gear set? I have no idea what caused the bolt to back out but it made a HUGE noise as it went through!

[special-K]

Originally Posted by propanemudtruck

Not to HiJack this thread, but I'd sure love to hear the rest of this story! Well the beginning of it would be nice too!

I guess I'll start a thread. Maybe make it a "Tales of the Off Road" for everyone's stories.

['63GENIII]

Originally Posted by special-K

I guess I'll start a thread. Maybe make it a "Tales of the Off Road" for everyone's stories.

'd like to hear what the outcome was too!

[barrolde]

Haha thanks guys, i'm going to swap out the whole axle for another d44 I found on the cheap.

See you in the offroad stories thread!

[msgross]

make sure the ratios are the same as your rear then... There should be a small ratio number stamped on the edge of the large ring gear. put that into a calculator and you'll get the ratio...

[barrolde]

Hello Friends, I am back again.. I became a father and the truck was but on hold but the wrenches are back out now. I haven't done anything with the front diff yet - couple of questions first if I may.

Is there such a thing as a limited slip front? My brother said that if I replace the gears as is that only one tire will spin in 4x4 is that right?

Finally does anyone have an opinion re: switching the gears out vs swapping the whole axle provided I can find one w/ 4.09's in it?

Thanks again guys.

[special-K]

Congratulations on being a father.

Yes,limited slips are used up front and are a good way to go. A locker-type of device is too harsh for the front axles because it steers and the tires need to spin at different rates.

Swapping a complete axle can be easier,and surely way less technical. It's a bolt-in deal. Setting up a ring & pinion takes some real care and can be pretty time consuming.