Everything you need to know! Let me preface this
a warning! If you have never set up a rear-end, used a case spreader,
used a dial indicator or a pinion depth gauge, you have no business
tackling this Dana 44/Salisbury Differential.
First, There are basically two versions of the
44/Salisbury Differential easily identified by the side stub axle
covers. One version has a 5 bolt retainer plate, the other has a
triangular 3 bolt retainer. Another major tech spec you'll need to know
is the side axle spline count It will be either 19 or 30.
I will concentrate the information for this
overhaul on a 19
spline Salisbury, since that's what I have.
I purchased all my parts for a Dana 44. Word of warning! It's
OK to order your differential carrier and ring and pinion for a Dana
44, but you'll want to buy your bearings, races and shims at a local
4wd store because a kit won't have all the correct bearings and you'll
just be wasting money!
Other important decisions you need to decide
before you start
your rebuild; 1.What size gears will I use? That will determine which
size carrier (or case) you'll need. There's a break at 3.73/3.92
Which type of carrier suits your purpose; limited
locker, air locker or possibly a spool! I used an Auburn Gear which was
the best price for the quality! Note: There is NO spool (full or mini)
available for 19 spline axles!
I won't bore you with setup specs because those
available at all the gear manufacturers sites!
Another important note if you plan to use a new
your Jaguar gears. The Jag gears use larger ring gear bolts. You'll
have to drill out your carrier holes and chamfer the edges for the Jag
ring gear to bolt on to the carrier! It'll work and it'll be fine! The
only factor you need to be aware of is, you cannot later buy different
gears to install on that carrier because the bolt shoulders are smaller
and your carrier will be drilled too large! You'll need to purchase a
new carrier or fabricate steel sleeves for the carrier (too much work,
I've done it)!
I will let you know that backlash and carrier
adjusted using shims that are behind the pressed on carrier bearings.
You will be removing and pressing these bearings on and off several
times! A nice convenience is having an extra pair of side bearings that
have the centers honed so they slide on and off the carrier easily
allowing you to press on the new bearings only for final assembly.
Pinion depth is adjusted by adding or removing
behind the inner pinion race.
Both sets of aftermarket gears that I purchased
did not use a
crush sleeve, so we won't go into it's purpose or adjustments.
One last note regarding the Pinion. You will now
have a 26
spline input shaft. You cannot use the Jaguar flange. Your local
4-Wheeler supply will have the Chevy yoke and U-bolts you'll need!
Here's my list of parts:
Bearings and Races
Carrier Bearings: 25590
Carrier Races: 25523
Pinion Bearing Inner: 31594
Pinion Bearing Inner Race: 31520
Pinion Bearing Outer: M88040
Pinion Bearing Outer Race: M88010
I have used 2 different Auburn Gear Carriers. I
the 5420111 Hi-Performance for Dana 44 3.92 up, 19 spline.
The input seal is a CR 15788
I'd also consider replacing the rear brake hose for about $12.
Part # N7000-42133 or IN102467