How Long to do a Dana 35 to Dana 44 Axle Swap?

[JMT]

How many hours should it take me to do an axle swap from the Dana 35 to Dana 44? I’m all ready with the shorter drive shaft for the Dana 44, brake fluid to gravity bleed the brakes, diff fluid for the Dana 44. I’m assuming I just remove teh breather hose, disconnect teh e-brake, disconnect the brake line, disconnect Upper and Lower Control Arms at the Dana 35, shocks at the lower bracket and the driveshaft. Then just move the Dana 44 under and start putting it all back together, torque everything down on the ground and then bleed the brakes. Sound good? How long do y’all think? 4-6hours???

 

[Jerry Bransford]

I swapped my 35 to a 44 in a morning. I don't recall exactly but it probably took three hours at the most. It was the first time I had ever done that so it could no doubt be done more quickly by someone who has done swaps before.

 

[tworley]

4-6 hours seems reasonable. I spent nine hours but I also wired a Rubi locker and had to remove a stubborn tcase drop with flush mount torx bolts and replaced 6 nutserts

 

[glwood]

If you're like me, about twice what you plan for.

 

[JMT]

I’m tempted to get to it today. Thanks for the estimates. Helpful...

 

[bobthetj03]

Git-er-done brah!

 

[Jeepers-n-Creepers]

If ya think some inspirational music would help ya, I can swing down that-a-away with "Thelma and Louise" (photo attached), and whup-up some Delta Blues to give ya some atmosphere in the garage (?)

 

[JMT]

Git-er-done brah!

I’m in it. Dana 35 off.

How do I get this metal retainer off so I can pull the shaft. This has to be simple!!!!

 

[JMT]

Anyone looking for a Dana 35 with 70k miles? I just found one on my garage floor.

Jeep looks naked

 

[Jeffreybomb]

As someone on a seemingly never-ending quest to replace the Dana 35 in his TJ, where did you find your Dana 44? Are you still running a Dana 30 up front? I've been told that swapping out the front axle for a Dana 44 is more trouble than it's worth.

 

[lindsey97]

What gear ratio in the Dana 35? Limited slip or open?

 

[JMT]

What gear ratio in the Dana 35? Limited slip or open?

3.73, open.

 

[JMT]

As someone on a seemingly never-ending quest to replace the Dana 35 in his TJ, where did you find your Dana 44? Are you still running a Dana 30 up front? I've been told that swapping out the front axle for a Dana 44 is more trouble than it's worth.

LOL. I found it on CL in Austin.

Dana 30 up front. No plans to change it out.

This has been a long quest. Hopefully I can finish up the swap tomorrow

 

[Jerry Bransford]

I've been told that swapping out the front axle for a Dana 44 is more trouble than it's worth.

It would be for me. The front axle seldom sees more than about 50% of the load/stress the rear axle does so it's normally good to go for up to 35" tires. Once you get both 35's and a locker into the front axle though it's time to upgrade its inner/outer shafts to 4340 alloys.

 

[JMT]

@Jerry Bransford , can you help me with my Q in post#8?

 

[Jerry Bransford]

@Jerry Bransford , can you help me with my Q in post#8?

I haven't had to remove one off a harmonic balancer like yours, I'm not familiar with how to do that. But why do you need to remove it? The OE driveshaft should be good to go for your Dana 44 so long as you have some suspension lift installed. Unless your Dana 44 is a Rubicon model which uses a different u-joint size on the driveshaft.

 

[Blackjack]

I’m in it. Dana 35 off.

How do I get this metal retainer off so I can pull the shaft. This has to be simple!!!!

View attachment 73026

You can mangle it with a pair of pliers or carefully open where it is crimped with a screwdriver.

 

[bobthetj03]

Just give it a yank, or cut the crimped clamp and replace it with zipties.

 

[bobthetj03]

I put the boot in the box with the ds if you eff yours up.

 

[Farmergreg]

Post 8 I think you need to cut that band where its crimped up and replace with new.

@bobthetj03 beat me to it!