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  #31  
Old November 9th, 2009, 22:51
fyrfytr1717 fyrfytr1717 is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

OK, time for an update... I've had my Super 44 kit sitting in my garage for way too long now. My machine shop took about three weeks to get the shafts done this go around. Apparently they were busy with their regular customer's jobs. Good news is I managed to save a bunch of money this time. All I brought in were my new shafts and the new set of tone rings. No pressing on or off of bearings or rings. Just a clear cut machining job. The job was completed for their 1 hour minimum shop charge of $80. Here's some before pics:

A Superior 33 spline Dana 44 shaft from the Super 44 kit



OEM ABS tone rings from a Dana 35 (Thanks Blazair)



The machinist told me the Superior shafts were a pleasure to work on compared to the OEM shafts. He said the center was much easier to locate and he especially liked that the entire surface of the shaft was already machined true unlike the cast surface of the OEM radius. Here's some after pics:

Superior beef with a side of ABS



A little closer up



I had the machinist use the bearing seat for the reference point this time. I figured it was an easy to measure from spot, could be used with bearings on or off, and is a fixed reference point that will be the same for all XJ Dana 44 axle shafts. I asked him to machine the tone ring seat 1.7" from the bearing seat, and to turn it until there was a clean surface that was at least .52" wide for the tone ring to press onto. He removed slightly more material than I expected (.055" vs .030") but it still worked out just fine. Here's the all important close-up with the dimensions laid out:



The final diameter ended up being 1.895" and that cleaned up the radius all the way from the tone ring seat to the beginning of the seal surface. The tone ring of course gets bored out to a slightly smaller diameter for an interference fit.

The tricky part of working with these shafts is that you just don't have much room to work with. It's hard to see in the above pics, but there is actually a small lip where the oil seal surface (1.875") meets the tone ring mounting surface (1.895"), and there has to be. If they were exactly the same size, you'd probably mar the sealing surface while pressing on the tone rings. If the oil seal surface was larger, you couldn't press the tone rings on at all as they wouldn't be able to fit over the sealing surface. The margin of error here is only about .040" so make sure your machinist knows what they are doing before they get started.

So how do my new measurements line up? I wish I knew... During what little free time I'm afforded with a 10 month old boy crawling around the house, I've been working my ass off trying to finish landscaping my backyard before the rainy season begins. This has left me with no time to install my new gears and lockers. Since I upgraded to 33 spline shafts, I can't even test fit them in the stock Dana 44 carrier. I'll post up as soon as any more progress is made.
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  #32  
Old January 4th, 2010, 17:28
chpalmer chpalmer is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Awsome writeup!

I personally hate ABS but am not willing to pull it on my 99 so came across your post while looking for a solution.

Anyone know a good source for new tone rings? Id like to keep my Cherokee on the road till the axle is finished. ABS and Disc Brakes...

Also- are 33 spline gears available for you stock carrier so you can use the axles with it??
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  #33  
Old January 4th, 2010, 18:07
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

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Originally Posted by chpalmer View Post
Awsome writeup!

I personally hate ABS but am not willing to pull it on my 99 so came across your post while looking for a solution.

Anyone know a good source for new tone rings? Id like to keep my Cherokee on the road till the axle is finished. ABS and Disc Brakes...

Also- are 33 spline gears available for you stock carrier so you can use the axles with it??
axle shafts are $15 a piece at my PNP, and a little PB and a press, and they pop right off.

33 spline gears are available for Detroits and ARB's (and maybe some others too)
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  #34  
Old January 23rd, 2010, 17:03
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Rob D Rob D is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Great write-up! I think I would have tried to do this also with my 35-spline d44 I'm putting together. But since I have a '91 with the truely crappy ABS system in it, I went with the "rip it out and throw it as far as I can" method instead. Thanks for the great write-up though.
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'91 Cherokee Larado, Full-Traction 6" coils w/ACOS's, 6.5" Clayton springs, 35" MTR's, 4:88's, 35-spline D44 w/ARB and Explorer disc's in back and a narrowed hp44 front w/E-Locker.
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  #35  
Old July 24th, 2010, 13:07
fyrfytr1717 fyrfytr1717 is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Well, my son is 18 months old now, I have new lawn in both my front and back yards, and it's finally update time! I bit the bullet and paid someone to install my new gears, lockers, and yes, axle shafts. The measurements I provided in my last post were dead on and everything lined up nicely! Here are some pics:

New Superior 33 spline axle shafts installed in the Dana 44



Good shot of the mounting bracket and sensor



And the centering mark on the sensor is right in the middle of the tone ring



And here's a pic of my completed (for now) XJ Super 44 with ABS, Spicer 4.56 gears, ARB, and a RuffStuff cover.



I can't believe how long it has taken to get to this point, but I'm very happy to have finally finished this project. I'm currently working on a related project that will allow me to disable the ABS system (and hopefully the airbags) for off road use by flipping a switch in the cab. Sure I could just pull all the fuses and relays when I get to the trail, but where's the fun in that? I'll post up details in another thread if/when I ever get that one all figured out. I'm also happy to report that my old ABS shafts have found a new home and are now living a happy life in another member's XJ.
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  #36  
Old July 25th, 2010, 06:29
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Quote:
Originally Posted by fyrfytr1717 View Post
I'm currently working on a related project that will allow me to disable the ABS system (and hopefully the airbags) for off road use by flipping a switch in the cab.
Looking forward to seeing this. With your attention to detail I'm certain it won't be the typical 4x4'ers bodge job.
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  #37  
Old July 25th, 2010, 23:09
fyrfytr1717 fyrfytr1717 is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

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Originally Posted by Root Moose View Post
Looking forward to seeing this. With your attention to detail I'm certain it won't be the typical 4x4'ers bodge job.
Thanks for the vote of confidence! My motto with pretty much all my mods is "keep it clean". Kastein is actually the brains behind the airbag portion of the project, I'm just planning on adapting it to suit my needs and then tying it in with an ABS override design of my own.
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  #38  
Old July 26th, 2010, 14:09
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kastein kastein is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

So what you're saying is that there are no brains behind that idea...

Reminds me, I gotta do some testing on that sometime soon. As usual, I have the parts sitting in the vehicle, just haven't tried it yet.
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My yard looks like Sanford & Sons.
Please do not PM me about the AW4 info thread unless you have a truly unique question that is not covered by it or info to add. I do not respond to questions answered by the thread.
Definitely do not hunt down my phone number at 3AM, text me about it, and then threaten violence when I am not helpful. It will not get you what you want.
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  #39  
Old August 8th, 2010, 12:57
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60anny 60anny is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

you are looking into putting on an ABS on/off switch???? great!!! that's what i have been looking into...hate ABS offroad passionately, but i cant imagine not having it in Colorado winters....have you found something that works?
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  #40  
Old August 21st, 2010, 18:16
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

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Originally Posted by SKJeep View Post
great writeup !!!

i did a sort of similar setup a while ago. It was a TJ with D44 rear, drum brakes and factory ABS so it had allready the tone rings on the shafts. We did rear disc conversion (using the conversion kit from Crown)

First i tryed to use ZJ ABS sensors, but they didnīt reach the tone rings.
(so now i know that the tone rings from drum axle are smaller than the disc ones)

We ended up exactly the same way - using the old abs mounts with welded tabs
A few years back when I installed a D44 and converted it to discs and ABS, I used the ZJ tone rings and the ZJ rear brake parts. They fit great. This is what they look like.
http://members.cox.net/nraok/rhabs.jpg

Last edited by xjman96; August 21st, 2010 at 18:25.
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  #41  
Old August 22nd, 2010, 20:57
fyrfytr1717 fyrfytr1717 is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

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Originally Posted by xjman96 View Post
A few years back when I installed a D44 and converted it to discs and ABS, I used the ZJ tone rings and the ZJ rear brake parts. They fit great. This is what they look like.
http://members.cox.net/nraok/rhabs.jpg


Sweet, thanks for sharing the pic! So just to get the story straight for anyone wishing to follow your lead... XJ D44, XJ axle shafts machined to accept tone rings, ZJ tone rings machined to fit the XJ shafts, and ZJ sensors installed as part of the ZJ disk conversion?
If not, please correct me. Thanks!
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  #42  
Old August 22nd, 2010, 22:20
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xjman96 xjman96 is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Quote:
Originally Posted by fyrfytr1717 View Post
Sweet, thanks for sharing the pic! So just to get the story straight for anyone wishing to follow your lead... XJ D44, XJ axle shafts machined to accept tone rings, ZJ tone rings machined to fit the XJ shafts, and ZJ sensors installed as part of the ZJ disk conversion?
If not, please correct me. Thanks!
You are correct on all counts. The shaft area was basically cleaned up on the lathe, measured and the tone ring diameter was opened up to match with .001" interference fit, I used a PVC pipe to install the rings on the shafts.
One thing I regret in this operation is that I tried to keep the Dana 44 axle factory and modify the small parts to fit it. I consider that a mistake because the axle flange is steel while the ZJ brackets are steel castings that become impossible to drill when welded because welding steel castings turns them diamond hard. If I had to do it again I would have welded the axle flange and drilled it to match the brackets. Assuming that I am right that the axle flanges are regular steel, I have not tested this.
Another point, the D44 pinion sticks out farther forward than the D35. That means that the rear propeller shaft is forced farther in to the transfer case. To avoid that I used a propeller shaft from 97-01 XJ with 8.25" rear for a perfect fit.

Off topic for a moment, the front axle knuckles get wear spots from the front disc brake pads. If that wear gets filled with weld, because they are cast steel, they will be so hard that will resist further wear.
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  #43  
Old August 23rd, 2010, 06:56
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kastein kastein is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Quote:
Originally Posted by xjman96 View Post
Another point, the D44 pinion sticks out farther forward than the D35. That means that the rear propeller shaft is forced farther in to the transfer case. To avoid that I used a propeller shaft from 96-01 XJ with 8.25" rear for a perfect fit.
Minor correction... transfer case output shaft design change was in 96. I learned through experience also that a 95-down style rear shaft and a 96-up style rear shaft differ in length by a significant amount, several inches, with all other drivetrain specs (axle, transfer case, transmission, engine) constant.

Quote:
Originally Posted by xjman96 View Post
Off topic for a moment, the front axle knuckles get wear spots from the front disc brake pads. If that wear gets filled with weld, because they are cast steel, they will be so hard that will resist further wear.
I have seen info on this repair and considered doing it, now I really need to get around to it! Mine are notched pretty bad.
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My yard looks like Sanford & Sons.
Please do not PM me about the AW4 info thread unless you have a truly unique question that is not covered by it or info to add. I do not respond to questions answered by the thread.
Definitely do not hunt down my phone number at 3AM, text me about it, and then threaten violence when I am not helpful. It will not get you what you want.
CTeunuch: Sometimes I really wonder if this sport makes you insane, or it just attracts the mentally unstable.
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  #44  
Old March 6th, 2011, 20:06
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tomcat tomcat is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

finally took pics of my XJ 44 with ZJ brakes setup to post up too

Parking brake by xjeep, on Flickr


Abs sensor passthrough by xjeep, on Flickr


Blocked bolt by xjeep, on Flickr


Backing plate by xjeep, on Flickr
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  #45  
Old March 6th, 2011, 21:32
fyrfytr1717 fyrfytr1717 is offline
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Re: THE XJ Dana 44, ABS, How-to thread (56K beware)

Thanks for sharing the pics tomcat! Do the ZJ sensors or mounts have to be modified to work, or do they just bolt right up to the ZJ brake bracket once you notch the flange? Also, I know the diameter is different, but are your tone rings located in the same position on the axle shaft as the tone rings in my drum brake set up? Just wondering how involved it would be should I decide to switch to discs in the future.

So far as the ABS portion of the project goes, this looks to be a heck of a lot simpler than trying to rework the sensor mounting brackets like I did for my drum brakes. No worrying about the sensor meeting the tone ring at the proper angle, if I'm understanding what you did correctly...
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