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  #1  
Old 05-16-2017, 07:38 PM
Harvey Harvey is offline
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1968 Wagoneer Rear Differential Nightmare-Help!

Hey, so there was a clunck in my rear end. I took out the carrier and there were no shims! Then I noticed looking at the inside of the rear this chunk of metal missing from the place where the side bearings go. Can you see it in the pict? This is bad right??! Think that is where the clunk noise comes from? Now, I did buy a 1967 Wagoneer parts truck[IMG][/IMG] and it has the same Dana 44, but it is a manual shift and my other is an automatic. Does it matter?? Can I take the entire axle from that and place it on my one in need of repair? I am an incompetent mechanic, but I am learning. Thank you!
http://i217.photobucket.com/albums/c...r/IMG_4229.jpg

Last edited by Harvey : 05-16-2017 at 08:39 PM.
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  #2  
Old 05-16-2017, 08:41 PM
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44BZ 44BZ is offline
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Both wags should have the same axle. I would just swap one for the other, assuming the gear ratios are the same.
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  #3  
Old 05-16-2017, 09:01 PM
Harvey Harvey is offline
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How do I tell what the gear ratios are? Really, I am very new to working on my own Jeep.
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  #4  
Old 05-16-2017, 09:34 PM
SJTD SJTD is offline
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Jack up one rear wheel. Count how many turns of the drive shaft to rotate the tire once. Divide that by two. (Or is it multiply by two? Should be obvious by the number you get.) (Only if no posi.)

Or jack up both rears and count how many turns of the drive shaft to rotate the tires once. Be sure both are turning together.

Or count the ring gear teeth and divide by the number of pinion teeth. This is the most accurate method.

Or check the tag held by two dif cover bolts if it's still there and you think you can trust it.
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Last edited by SJTD : 05-17-2017 at 09:07 AM.
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  #5  
Old 05-16-2017, 11:28 PM
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Kaiserjeeps Kaiserjeeps is offline
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Quote:
Originally Posted by Harvey
Hey, so there was a clunck in my rear end. I took out the carrier and there were no shims! Then I noticed looking at the inside of the rear this chunk of metal missing from the place where the side bearings go. Can you see it in the pict? This is bad right??! Think that is where the clunk noise comes from? Now, I did buy a 1967 Wagoneer parts truck[IMG][/IMG] and it has the same Dana 44, but it is a manual shift and my other is an automatic. Does it matter?? Can I take the entire axle from that and place it on my one in need of repair? I am an incompetent mechanic, but I am learning. Thank you!
http://i217.photobucket.com/albums/c...r/IMG_4229.jpg

Manuals and auto rigs most always had different gear ratios. The chunk missing is an odd spot for that to happen. You need to remove the pinion and check the oil cavity in the bottom of the housing for broken chunks. They will come to rest there. If all the gear teeth are fine on both the pinion and ring gear, with no damage then they can be re set up and used in a properly set up condition. The teeth count is stamped in the shank of the pinion. Divide it with a calculator and it will tell you exactly what it is. Using the tire rotation method works but you need to see what it is exactly if you end up replacing the gears.. Like 4:09 or 4:10 or even 4:11 make sure match it exactly. They might even be 3 series gears.
Setting up gears is very doable but if you have not before, it can be very frustrating. I also might be willing to bet you don't have the right tools and the other thing is understanding what happens to the gear contact pattern when you move a shim. If you don't have a solid grasp on this you will have a rough time. I would suggest having it done this time around if you reuse those gears and differential.
Now find the chunk for sure. You can see if it has been gone a while by discoloration in the casting. The other thing is, is that a crack in the upper bearing cap contact face? And if that housing is ever used again, the 2 dents in the lower mating surface need to have the high spots filed flat so the bearing cap meets the casting correctly. If there are no cracks or damage elsewhere, you should be able to use that housing again. Look at the witness mark the carrier bearing race left. The missing area does not get into that. Someone also put that diff in with dirt under the carrier bearing cap. See the two dents just behind the axle from junk being tightened and squished? Make sure it is super clean.
The break point for a 3 series gear set (example 3:54 or 3:73) and 4 series gear set (example 4:10 or 4:27 or 4:56 ) on the diff carrier is 3:92 for a dana 44. 3:73 is a 3 series diff. And 3:92 and up are a 4 series diff. So if your other axle has say 3:54 gears, you can not put 4 series gears on it. You need a 4 series diff carrier. How do you tell besides knowing the ratio?? The ring casting where you bolt the ring gear up to is a different height if you set both differentials on a table with the ring gear facing up. So don't start mixing up the axle parts till you know what you have. If you are lucky, the gear ratio will be the same on the spare axle. Then just bolt it in.
Shims on that style axle for backlash should be on the inside of the carrier bearings between the diff and the bearing. On both sides. Not behind the race. If it was run long without being properly set up, chances are the gears have worked through the face hardening on the teeth and are ruined. Close examination should reveal that. Hopefully it won't take much to get it fixed.
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Last edited by Kaiserjeeps : 05-16-2017 at 11:34 PM.
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  #6  
Old 05-17-2017, 07:47 AM
440sixpack 440sixpack is offline
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Most of the time the ring gear will have the ratio stamped on it. if the axle from your parts rig is the wrong ratio you could always swap out both axles from it it's not that much work. or just find the right one , narrow track axles are cheap. around here anyway.

Setting up a rear end isn't something I'd recommend for a novice mechanic.
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  #7  
Old 05-17-2017, 02:50 PM
rocklaurence rocklaurence is offline
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Quote:
Originally Posted by 440sixpack
Most of the time the ring gear will have the ratio stamped on it. if the axle from your parts rig is the wrong ratio you could always swap out both axles from it it's not that much work. or just find the right one , narrow track axles are cheap. around here anyway.

Setting up a rear end isn't something I'd recommend for a novice mechanic.

X2--the ring gear has the ratio at the end of all the numbers . For example: 46.13 Which means 46 teeth on ring and 13 on the pinion= 46/13
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  #8  
Old 05-17-2017, 09:54 PM
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Kenall Kenall is offline
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as for the gear ratio in a 68 wag..i vote for 331 as the pinion is 13 teeth, the ring gear I vote will have 43 teeth.
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  #9  
Old 05-18-2017, 09:00 AM
SJTD SJTD is offline
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Looking at the numbers on the ring will work too.

The 4.09, 4.10, 4.11 confusion wouldn't apply would it? Didn't it only come in one of those? Like the Dana 60 was 4.10, the 44 was 4.09 etc?
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  #10  
Old 05-18-2017, 10:22 AM
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Kaiserjeeps Kaiserjeeps is offline
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Quote:
Originally Posted by SJTD
Looking at the numbers on the ring will work too.

The 4.09, 4.10, 4.11 confusion wouldn't apply would it? Didn't it only come in one of those? Like the Dana 60 was 4.10, the 44 was 4.09 etc?

Trucks usually had the 4 series gears. Wags 3 series. My only point was to match the exact ratio just in case it was like the above and had been changed. So the rear would not try to override the front in slippery conditions and make a sketchy driver.

Just an example is all.
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Holy Moly, I am done.....

Most users ever online was 656, 06-30-2007 at 09:50 PM.
I was there! Still waiting for my Tee shirt...

1969 1414X Wag,
71 project J truck FOR SALE
1970 J truck long bed bed FOR SALE
1970 Wagoneer Not Sadie
1983 FJ60 wagon
CJ-5's
83 CJ-7 excellent shape FOR SALE
And soon... Another M715! echo... echo...
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  #11  
Old 05-25-2017, 08:46 AM
rocklaurence rocklaurence is offline
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My understanding is 1-2% is allowed. So, 4.09/4.10/4.11 are all compatible with each other. I've seen almost every variation of gear ratio available for the D44s.
Consider having tires from different manufactures on the front and rear. Their tires of the same advertised size vary more than 2%.
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  #12  
Old 05-25-2017, 09:43 AM
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swampedge swampedge is offline
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Check the tag on the differential cover if it's still there. I vote 3.31.1 also.
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