I am just beginning to work on a Dana 44 out of a Comanche (right width, right bolt circle, bigger brakes, getting new brackets) to put it on my TJ. Does anybody know of any particular weaknesses I should be addressing in the 44 as I am rebuilding it? I am looking at doing 5.39 gears to get back essentially stock performance (35" tires) and this would mean removing the Dana 30 in front and putting a 44 in there also. so the questions are...
1. Where do the Dana 44 gears start to become weaker as the gears get lower? 4.88? 5.39? 5.89?
2. How strong is the carrier? Do they stand up well to a Lock-Rite? or do I need to put in a Detroit (which I might anyway, but I am real curious if they stand up to a Lock-Rite OK)?
3. Are there any other known Dana 44 problems (bearings, tubes bending, etc.) that I need to know of and address?
98 TJ, 4 cyl, 35" tires, 4:1, 4" sus lift, 1" BL/MM