Dana 44 re-gear and locker install

machoheadgames said:
It amazes me that people will work on diffs and yet still somehow either not know or care that the bearing caps go on in a certain orientation.
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Word. Im an absolute noob at diff work, and even i saw that and thought "that dont seem right!"

With the help of folks on this forum, it's actually a really doable job, but you have to be detail oriented and take your time. It amazes me that someone would get into a project like this and rush, or ignore details.

But... I guess I know why I got the axles so cheap, now!😆
 
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Finally had time to get to stripping the axle and cleaning everything today. Got everything mocked up before I ran out of steam. (The air line is just looped around the housing so I can throw the cover on for the night.)
20250904_163706.jpg

It's in, but the backlash is way too tight. It's fine, though, because im super excited to be at the point where I can start chasing a pattern! Tomorrow I'll be pulling some shims from behind the pinion and starting actual gear setup!

Wish me luck, boys!
 
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Super close to running patterns, guys. Im working night shift, so i didnt start monkeying with it till 11, but I had to take a break to run to a Dr's appointment and pay bills. Backlash is currently at .005, so I need to get just a little more, and I'll start posting patterns. Expect a post by late afternoon!
 
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First pattern. Definitely shallow. Gonna add 20 thou and see what comes.

pinion: .040
driver: .195
Passenger: .105
B/L: .008
20250905_145956.jpg
20250905_145938.jpg
 
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Better, but maybe too deep, now?

What say the experts?
Pinion: .060
Driver: .190
Passenger: .110
B/L: .006
20250905_155720.jpg
20250905_155659.jpg
 
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Pattern 3. I think this is close. Im gonna stop until I get feedback on the above 3 patterns.

Pinion: .050
Driver: .190
Passenger: .210
B/L: .008
20250905_163550.jpg
20250905_163529.jpg
 
Super frustrated. Can't bet backlash right on this most recent one. I've been at .004 and .011, but am struggling to get it between .006 and .010 per spec. Im gonna take a break, cook dinner, then try again. Working overnight tomorrow, so I have to stay up till 3 or 4 anyway, so I might as well monkey with it tonight.
 
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97TJNM said:
Super frustrated. Can't bet backlash right on this most recent one. I've been at .004 and .011, but am struggling to get it between .006 and .010 per spec. Im gonna take a break, cook dinner, then try again. Working overnight tomorrow, so I have to stay up till 3 or 4 anyway, so I might as well monkey with it tonight.
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Just keep working the shims back and forth. Patience is absolutely necessary with this.
 
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Pattern # 4

pinion: .070
driver: .185
Passenger: .115
B/L: .007

I definitely am glad I stepped away. I was frustrated, lost my shim needed to add just 5 thou, added 10 thou to pattern number 2, and couldn't get my backlash in spec.

After a couple hours chilling with the family and eating dinner, I sorted out my shims, reset, and was able to find backlash spec in 10 minutes.

i know i went deeper than you said to, @hosejockey61 so if this patter looks too deep, let me know and I'll pull out 5 thou.
20250905_230832.jpg
20250905_230102.jpg


20250905_230102.jpg
 
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I was trying to get you to go deep so we could identify your bracket. Now you know the range of too shallow and too deep. Your pattern will be found somewhere in between. I don't know what you added this last time but take out 5 and let's see what it does.
 
Pattern #5
Pinion: .065
Driver: .185
Passenger: .115
B/L: .007

pics of both pattern and ghost pattern. What say you guys?

20250906_141744.jpg
20250906_141758.jpg
20250906_141833.jpg
Screenshot_20250906_142751_Gallery.jpg
 
hosejockey61 said:
It looks like you're very slightly deep. Try removing 2-3 thou
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Thank you for all your help, man. That said, I have a question that I hope you can shed light on. My two closest patterns were my second one (post #45 which was slightly shallow) and my last pattern (post #55 which was slightly deep). Are either of those acceptable? Please understand, I know that gear setups are precise and require patience. I have no issue rearranging shims and running another pattern if that is what it needs.

The reason I ask is because Revolution's pinion shim stacks suck. They send you a 20, a 15, and five 10's. Making anything outside a multiple of 5 is impossible.

If neither pattern is runnable, do you have a suggestion on where to buy shims that actually have a variety that can cover different numerical depths?

Sorry for the wordy ask, but Revolution has me frustrated.

What kills me is their carrier shims actually have quite a variety. I have 3's 4's, 6's and a 7. I dont know why they send such a limited shim pack for pinion depths, though.
 
I'm out at a charity event for the rest of the night. I'll look first thing in the morning. That's the thing that has driven me nuts, and it's just not Revolution, but all the gear suppliers. You have to buy shims separately to get any odd size and thinner shims.

A lot of gear installers now sell an extended warranty which allows them to get it close enough, which saves then time in the short run. I hate that people don't take pride in their work anymore. Time is money I guess, but whatever.
 
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hosejockey61 said:
I'm out at a charity event for the rest of the night. I'll look first thing in the morning. That's the thing that has driven me nuts, and it's just not Revolution, but all the gear suppliers. You have to buy shims separately to get any odd size and thinner shims.

A lot of gear installers now sell an extended warranty which allows them to get it close enough, which saves then time in the short run. I hate that people don't take pride in their work anymore. Time is money I guess, but whatever.
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I appreciate you taking the time to look at it closer tomorrow. That said, I'll research pinion shims and prepare to order some if you dont think either of the 2 patterns in question are runnable.

In the end, if I have to add a week to this process waiting on new shims, it's better than having to do this whole process again in a year because I tried to rush getting it right.
 
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97TJNM said:
I appreciate you taking the time to look at it closer tomorrow. That said, I'll research pinion shims and prepare to order some if you dont think either of the 2 patterns in question are runnable.
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I hate to say this but my Yukon kit came with a lot of shims. Junk R&P, but...
97TJNM said:
In the end, if I have to add a week to this process waiting on new shims, it's better than having to do this whole process again in a year because I tried to rush getting it right.
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Yeah take your time. Mine sat in my garage for close to 3 months. It was worth it
 
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