D44 pinion vs. 8.25 pinion

ThePhantum · Apr 13, 2004

So I've decided to put a D44 in the 97 (instead of the 8.8 I was thinking about). I should be picking one up this weekend from a guy in MD. Here my question: What is the difference in the pinion length between a D44 and an 8.25?

I know that the D44 is about an inch or so longer than the D35, but I'm not sure about the D44 vs. 8.25.

Basically I need to know if I need to get a shorter (or longer) driveshaft as well.

Thanks.

Steve

Wayne Sihler · Apr 13, 2004

Just did the same swap 500 miles ago.8.25 out,D44 in,It looked to me that the drive shaft moved out(longer) when attatched to the 44.This was eye-balling the wear area under the grease seal.
Wayne

ThePhantum · Apr 13, 2004

Wayne Sihler said:
Just did the same swap 500 miles ago.8.25 out,D44 in,It looked to me that the drive shaft moved out(longer) when attatched to the 44.This was eye-balling the wear area under the grease seal.
Wayne

So then it sounds like you just used the existing shaft? What about the diff yoke...did it require a different u-joint?

Steve

ChuckD · Apr 13, 2004

ThePhantum said:
So then it sounds like you just used the existing shaft? What about the diff yoke...did it require a different u-joint?

Steve

An XJ D44 is a direct swap for an XJ 8.25. The only difference maybe the length of the rear drive shaft. Ujoints are exactly the same.

Wayne Sihler · Apr 14, 2004

ChuckD said:
An XJ D44 is a direct swap for an XJ 8.25. The only difference maybe the length of the rear drive shaft. Ujoints are exactly the same.

It is not a direct swap.The DS u-joints and length are,but the axle tubes are smaller on the D44 and require different U-bolts.
Running a RE SYE and DS so I,m not stock in the DS department,but all are stock size u-joints.
Wayne

ThePhantum · Apr 15, 2004

Yea, I knew about the axle tube differences requiring different u-bolts. Even if the tubes were the same size I would get new ubolts...

I was more concerned about the driveshaft length and whether or not the ujoints were the same or not.

Thanks for all your responses.

Steve

ChuckD · Apr 15, 2004

I have an MT,
My OEM drive shaft and extended slip yoke has worked for all the axles I have had. Originally I had an 8.25 and then an 87' D35 and now an 87' D44. Same shaft worked for all of them.

Right now I have an SYE with a spicer DoubleCardan. It has worked with both my D35 and D44. I had to add 1" of lift for the D44, it has a longer snout.

marcusguy · Apr 15, 2004

When I did this swap on my 99, something I had to deal with was the difference in how the brakeline attaches to the housing. It isn't that big of a deal but on the 8.25 the breather tube is also the bolt that holds the brake line T to the housing, so it has a big hole in it for that reason. On the 44 I got, there was a small bolt to hold the brake line and a small seperate breather off to the side. Anyways, just thought you should know.

marcus

jjvande · Apr 15, 2004

yea...went from D35 to D44 and used the same TW CV shaft. the difference in length was about .5" and wasnt a problem at all. THe jeep's at 6" in the rear.

-J

Wayne Sihler · Apr 15, 2004

marcusguy said:
When I did this swap on my 99, something I had to deal with was the difference in how the brakeline attaches to the housing. It isn't that big of a deal but on the 8.25 the breather tube is also the bolt that holds the brake line T to the housing, so it has a big hole in it for that reason. On the 44 I got, there was a small bolt to hold the brake line and a small seperate breather off to the side. Anyways, just thought you should know.

marcus

Thats right,the breather tube on the 44 is a pushed in plastic part,the 8.25 is a brass combination piece that holds the brake line block and is a vent attachment.
If you have the 44 axles out,the vent hole can be threaded to accept the new hollow bolt,the thread is a bastard size 7/16-20.The brake attachment hole is 1/4-20 and could be closed off.
The YJ brake hose I used had this larger hole.
If you want to reuse the steel brake lines the smaller hole could be drilled and tapped larger then you would have two vents
HTH ?
Wayne

ChuckD · Apr 15, 2004

I used 1/8" pipe thread, you can find brass pipe fittings at Lowes. I did mine and was able to tap it with out drilling out the hole. Now I have a nice 90 degree brass fitting.

D44 pinion vs. 8.25 pinion

ThePhantum

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Wayne Sihler

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ThePhantum

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ChuckD

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Wayne Sihler

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ThePhantum

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ChuckD

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marcusguy

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jjvande

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Wayne Sihler

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ChuckD

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