Dana 44 with aftermarket cover - fill capacity concerns

  • Thread starter Thread starter mojowrangler
  • Start date Start date
Rubicon 44's with stock air actuated lockers.the small 3/16 hose above the vent tube is the air line from the tiny pumps on the skid. The big electrical connector is for the dash lights

@Rickyd Thanks, that helps. The big electric connector in the front was disconnected when I got it. I assumed that it also engaged the lockers, but I did notice the indicator light on the rocker switch started working when I got this reconnected. I still need to replace it eventually (damaged and held together with electric tape and zip ties right now).
 
FWIW< I'm not trying to be a jerk but the 216 is the front differential and the 194 is the rear although we're not sure exactly what you have...yet.

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That page I posted is from the 1997 FSM so I'm pretty sure the 194 indicated here is the Dana 35.
 
@JEEPCJTJ Just to clarify, my Jeep is a '97 Sport, but I was told by the previous owner that the axles are both Dana 44s from an '04 Rubicon. The axles do appear to be Dana 44s from the cover bolt pattern and from various comments from folks (nobody has disputed that as far as I know). So for anything related to the axles, I am referring to the '04 manual. I think this makes the most sense. The reference you posted is in line with everything I've read so far, if my Jeep had stock axles.

The caveat to all this is that I'm not sure how to positively identify the specific axle models other than Dana 44 (e.g., if the previous owner was wrong about the '04 Rubicon origin) since Dana 44s appear to fluctuate in gear oil capacity specs. The spec might also deviate with the aftermarket valve cover (I haven't had much time to look into this yet). Others have pointed out how I could achieve the proper fill level based on the axle height, and how the fill level might correct itself a little via the vent tube. However, at this point I've refilled the axle twice and plan to leave it at a little over two quarts each. I will also try to monitor any spillage from the vent tube as it gets driven. If I suspect the 2 quart spec is off, I will revert to the manual fluid check others have suggested (looking at fluid level with respect to the axle, ignoring the manual specs). I'll also try to make a note of this for the next time I change the gear oil.

All the feedback on this form has been really helpful and greatly appreciated!
 
@JEEPCJTJ I assumed "Model 44" referred to the Dana 44 axles, which are both listed as "261 RBI (Model 44)" on the page I referenced. "194 RBI" is another rear axle associated with "(Model 35)", which I assume is commonly referred to as the Dana 35.

I just crawled under the Jeep and took a bunch of pics. I'll post them...

I just had to double check myself and you're more right than what I posted. For some reason I was thinking that the numerical part of the front and rear axles were different when in reality they're both 216 with the difference being 216FBI in the front and 216 RBI in the rear.
 
@JEEPCJTJ Just to clarify, my Jeep is a '97 Sport, but I was told by the previous owner that the axles are both Dana 44s from an '04 Rubicon. The axles do appear to be Dana 44s from the cover bolt pattern and from various comments from folks (nobody has disputed that as far as I know). So for anything related to the axles, I am referring to the '04 manual. I think this makes the most sense. The reference you posted is in line with everything I've read so far, if my Jeep had stock axles.

The caveat to all this is that I'm not sure how to positively identify the specific axle models other than Dana 44 (e.g., if the previous owner was wrong about the '04 Rubicon origin) since Dana 44s appear to fluctuate in gear oil capacity specs. The spec might also deviate with the aftermarket valve cover (I haven't had much time to look into this yet). Others have pointed out how I could achieve the proper fill level based on the axle height, and how the fill level might correct itself a little via the vent tube. However, at this point I've refilled the axle twice and plan to leave it at a little over two quarts each. I will also try to monitor any spillage from the vent tube as it gets driven. If I suspect the 2 quart spec is off, I will revert to the manual fluid check others have suggested (looking at fluid level with respect to the axle, ignoring the manual specs). I'll also try to make a note of this for the next time I change the gear oil.

All the feedback on this form has been really helpful and greatly appreciated!

The combination of sensor,drain plug,and air locker make them 03-06 wrangler rubicon specific.they are a very distinctive axle