Dana 44 axle swap Big vs Small Tube

[BrianG]

Hello, after hours of searching, I can't seem to find an answer to this question.

I have two Dana44 Axle assemblies. I'm trying to make one. The one that is under the truck which I am rebuilding is a smaller tube (older I believe) unit. I just replaced the ball joints and am half way through with the axle u-joints. I needed some parts off the other housing that I have so I tore it apart. Upon doing so, I realized that the axle shafts are much thicker in diameter on the one that is not under the truck. I also realized that the one out of the truck has bigger axle tubes. I believe the one that is out of the truck is around 76 or 77 and the one under the truck is possibly a 69. I am planning on using the hubs and spindles from the newer unit. ...... So, my big question is, can I, or should I use the heavier axles from the big tube dana 44 in my small tube dana 44 housing. The lengths seem the same, the splines all match up, only the thickness seems different. I've read and read about differences in the u-joints, but I have installed one already and it seemed to go in with not issue, so I think I'm good there.

Any and all help would be greatly appreciated.

[Orange Crate]

I had the same situation as you. I needed to rebuild my 44 under my 72 K20 (seals and bearings) but it was my daily driver so I found another decent axle with matching gears and swapped them out so I could continue driving. The spare axle I bought had the larger diameter axle shafts. My original axle has the thicker wall axle tubes (for 3/4 ton I am guessing). After I put the new parts in my original I swapped them out again and put the larger diam axle shafts into my original and sold the spare (with smaller shafts) Perfect! Info here:

http://77cj.littlekeylime.com/web_rs44.html

[BrianG]

Originally Posted by Orange Crate

I had the same situation as you. I needed to rebuild my 44 under my 72 K20 (seals and bearings) but it was my daily driver so I found another decent axle with matching gears and swapped them out so I could continue driving. The spare axle I bought had the larger diameter axle shafts. My original axle has the thicker wall axle tubes (for 3/4 ton I am guessing). After I put the new parts in my original I swapped them out again and put the larger diam axle shafts into my original and sold the spare (with smaller shafts) Perfect! Info here:

http://77cj.littlekeylime.com/web_rs44.html

Thanks Orange Crate. By "thicker wall axle tubes" do you know if those come from the smaller overall outside diameter axle tube housings, or from the larger. I couldn't swap the whole thing over because my top spring plates and ubolts are all for the smaller axle tube housing.

Also, In my original post, I mentioned that I thought the original was maybe a 69. I don't think that's right because it is an open knuckle Dana 44. I've always told them its a 72 at the parts store and most always I get the right parts.