1997 Jeep Wrangler TJ - Dana 44 Axle Buildup

Project Teal-J II, Intro
Project Teal-J II, Part 1
Project Teal-J II, Part 2
Project Teal-J II, Part 3
Project Teal-J II, Part 4
Project Teal-J II, Part 5
Project Teal-J II, Part 6
Project Teal-J II, Part 7
Project Teal-J II, Part 8
Project Teal-J II, Part 9
Project Teal-J II, Part 10
Project Teal-J II, Part 11
Project Teal-J II, Part 12
Project Teal-J II, Part 13
Project Teal-J II, Part 14

When it came time to focus our attention on the rear axle in Project Teal-J II, our original thought was to yank out the stocker and replace it with a custom axle. The more we thought about it, though, the more we were inclined to keep the original Dana 44 still residing under our '97 Jeep TJ. These days everyone seems to be talking about how Dana 60s are the best thing since peanut butter and chocolate.

Yet the Dana 44 is a tough axle that can take a good amount of abuse on the trail, especially in a light vehicle such as our Jeep. Plus it was already in our Jeep, so we didn't have to swap it out. Keeping the axle would also be a lot more cost-effective than building a whole new custom housing.

Another reason we decided to keep our rear Dana 44 involves the availability of the Super 44 axle kit from Superior Axle & Gear. Designed for '97-and-up Jeep Wrangler TJs, the Super 44 kit includes stronger 33-spline axles, a Detroit Locker and all the necessary bearings, shims and seals to complete the job. The new axles are larger in diameter and also feature rolled splines that are, according to Superior, up to 40 percent stronger when compared to stock axles. The axles also feature dual bolt patterns for 5-on-41/2 or 5-on-51/2 wheel patterns.

To handle the installation, we went to the pros at Drivetrain Direct. We found that the installation was fairly simple for someone experienced with setting up axles. It only took a couple of hours to make our Dana 44 stronger. Follow along as we show you what is involved.

The very first step is to take the brake drums off the rear to allow for access to the flange bolts.
The very first step is to take the brake drums off the rear to allow for access to the fla
Next the rear driveshaft was unbolted and hung out of the way.
With the brake drums removed, the axle flange nuts can be removed.

Once the flange is loose, the stock axles can simply be pulled out of the housing.
With the cover off and the gear oil drained, the bearings caps can be removed. Next, our original Detroit Locker was removed.
With the cover off and the gear oil drained, the bearings caps can be removed. Next, our o
Once the pinion bearing was extracted, the pinion itself was removed, along with all the bearing races.
Once the pinion bearing was extracted, the pinion itself was removed, along with all the b

Brake cleaner was then used to clean out the inside of the stripped housing.
You can reuse your existing gears but since we were going to run bigger tires, it was the perfect time to install a new set of 4.56 gears, also from Superior. Once the pinion bearing was pressed on, the pinion gear was put into position.
You can reuse your existing gears but since we were going to run bigger tires, it was the
Next, the new bearings included with the Super 44 kit were pressed onto the new Detroit Locker. If you already have a locker like we did, you cannot reuse it with this kit because the Detroit Locker that comes with the kit is built to accept the larger axles with more splines.
Next, the new bearings included with the Super 44 kit were pressed onto the new Detroit Lo

The new Detroit Locker can now be slid into position. It is a bit tricky because the shims on this Detroit Locker are actually on the outside of the bearings. While this makes installing it a bit more of a chore, it does make adjusting the shims easier as the bearings don't have to be pulled off.
The new Detroit Locker can now be slid into position. It is a bit tricky because the shims
With the locker in place and bearing caps on, backlash was checked to make sure it was within the proper range.
With the locker in place and bearing caps on, backlash was checked to make sure it was wit
Next, the pattern was checked, and it was fine. Gears set up the right way will make contact in the middle of the gear, just as you see here.
Next, the pattern was checked, and it was fine. Gears set up the right way will make conta

Now it was time to install our new, stronger axles. With the axle bearings in place, the retaining rings were pressed on.
Now it was time to install our new, stronger axles. With the axle bearings in place, the r
The new Superior axles are stronger than the stockers for several reasons. First, they feature a larger diameter of 1.42 inches and 33 splines compared to the 1.31-inch diameter of the 30-spline stock axles. Also, the Superior axles are made of a heavy-duty alloy and feature rolled splines. You can also see here where the stock axles (bottom) neck down while the Superior axles do not. All of these features add up to make for a much stronger axle.
The new Superior axles are stronger than the stockers for several reasons. First, they fea
Once the new axle bearings are in place along with their retainers, the new axles can be put into the housing. Then the flange can be bolted down.
Once the new axle bearings are in place along with their retainers, the new axles can be p

The final step is to throw on the brake drums, reattach the driveshaft, put the diff cover on and fill the axle with gear lube. After that, go hit the trail and enjoy the stronger axles.