Helpful write up & pics on Dana 44 rear install
 

Okay, This will be my first write-up using photobucket. I'll try to make this straightforward, but please forgive me as I'm not that computer literate.

I got a 44 rear out of an 87 Cherokee on New Years day for 75 bucks. Half-off. I've seen these 44's in 87 years only, but not every 87 has one. I took some measurements in hopes that the info provided will be benifical to others on here.

I've never done a rear end swap that was as easy as this one. It's basically like swapping a 12 bolt in place of a 10 bolt. I didn't have to change anything minus the rear hose- I cut it at the yard with the intent of replacing a 20+ year old hose. As someone mentioned before, the U-bolts and pads from the 44 will have to be re-used. The Chrysler rear end tube diameter is 1/4" larger, meaning that the U-bolts are different

Attachment 392439

As you can see the drums are quite a bit bigger from the 93 model Chrysler 8.25

Attachment 392440

Attachment 392441

Here are some measurements that I took.

8.25 axle tube O.D.- 3"
D44 axle tube O.D.- 2 3/4"

Attachment 392442

I measured both jackstands for their height. They were about 1/8" off- close enough for hand gernades. From the yoke to the ground on the 8.25 is 2-3/4". The yoke to the ground on the D44 is 2-1/4". Now that's a 1/2" difference, but keep in mind that the difference in tube diameter is 1/4", then you need to take the radius of a 1/4 dia= 1/8. This means that the driveshaft length wouldn't be off much.

Attachment 392443

When the Jeep was on the ground sitting level, I measured 2-1/16" from the end of the tailshaft seal to the flat spot on the slipyoke. Once the 44 was installed, I put it on the ground and jumped on the bumper. I then remeasured the above on the slip yoke, and came up with 1-3/4. This means that the 44 pushed the slip yoke into the tailshaft 3/8". Proof positive that you don't need to take the shaft to a shop (assuming that your swapping out your old 8.25, and not a D35). The Dana 35 is even smaller than the Chrysler 8.25, and I have no measurements for that swap.

I did the exact same swap on my 1991 XJ. I removed the 8.25 and replaced it with a D44 out of an 87 XJ. It was a complete bolt in. Nothing else had to be replaced

Well, that isn't entirely true. The brakes were nasty so I replaced them. Since installing the D44 into my 91, I also installed 4.56 gears and an Aussie Locker. It really was a complete bolt in. The gear ratios were even the same when I installed the D44.

Where did you get your gears at? Do you have a part number? I am really interested. I just picked up my 44 tonight.

Thanks

Were you using the forklift as a vehicle jack? :lol: