This is my first build thread so heres the run down. I own a '91 Cherokee Laredo with the stock Dana 30/35c turds underneath. Ive had no troubles with the 35 even with factory LSD, 33" mudders, and several wheeling trips a season. But now its time to get some more altitude(lift) and 35" tires. That being said, its time for a bigger rear axle.
Ive been on the look out for a used axle for quite some time now and I honestly couldnt make up my mind on what axle to go with. I narrowed it down to a D44, 8.8, or a 9". The deciding factor was the deal I came across. A 1971 Scout II 800b Dana 44 for $60 bucks. It has 3.37's, factory LSD, 57.1" WMS to WMS, and was already removed from the Scout.
Hopefully this helps anyone out wanting to do the same thing and save you some money by looking for dif alternitives on axles.
So here it goes... My attempt to rebuild and swap this Dana 44 into my '91 XJ.

 

Heres the axle with the factory perches removed.

 

All cleaned up and pretty! Almost looks new. I know I still have welding to do, but Im waiting on the new build components and got bored. LOL!

Stay tuned for inner and outer seal removal and installation.

 

Also, Im custom building a truss for the D44 like the onw from TNT Customs. Not gonna spend close to $200 bucks on something I can make.
Heres one of the templates.

 

loooking goood cleaned up really nice, keep us posted cant wait to see it in!

 

More custom truss mock up pics. Just gotta transfer it to some 3/16 metal and plasma it out and weld it up. Saving over $100 bucks over the TNT Customs truss by doing it myself.
Let me know if anyone wants the pattern or wants me to build one up for them. I will have the D35 truss mocked up once the D44 is in. Can also do an 8.25 as well.

 

Wms to Wms on the the axle? Wheel bolt pattern?

 

Wheel Mounting Surface. So its measured where the back of the wheel mounts to drum or rotor on both sides. Basically its the total length of the axle not including the wheel bolts.

 

Man, that axle is looking sharp!

 

Thanks! Its amazing what a can of spray paint and some ceramic powder coating can do. I even rattle caned the dif cover bolt heads. LOL
Im so bored! I wish I had more parts in so I could do more work on it or some metal I could weld!

 

I know what it means, I was asking what it is on your axle. Missed it in your first post, got it now.

 

LOL My bad. Its been a really long day.

 

haha i love that tin of grizz in the background lol, but i'm more of a mint fan myself

good luck with the build

 

LOL! I go back and forth between straight and mint.

 

So Im getting ready to take out my carrier so I can get at the inner seals, but not mess with the pinion gear. Will I have to mess with the back lash or any of the pian in the butt stuff if I dont mess with the pinion?