The Dana 44A is different from the standard D44 because of the aluminum outside the center section.
You’ll also notice that the parts for the Dana 44A are just a little bigger than the D44, which means you won’t have compatibility between the two.
When this axle gets equipped with the Dodge Viper, you’ve got an excellent product that delivers impressive results under most driving conditions.
If you have a Jeep Grand Cherokee, you might have needed to get it rebuilt or replaced under warranty. The issue with the D44A is that the pinion doesn’t stay tight in the housing. Once things start going out of spec, the unit would often eat itself alive.
Dana 44A Strength?
The problem with the Dana 44A is its aluminum center section. It has a reputation for breaking under heavy crashing or dashing, whereas the cast-iron version might come away without a scratch. Aftermarket skid plates work to address this issue, but an unprotected D44A is a potential liability.
Dana Holding Corporation produces the D44 and D44A automotive axles. It’s used extensively by numerous automakers, and it also has a significant presence in the aftermarket arena.
The original Dana 44 axle was manufactured in the 1940s, and the design is still in use today. There are front and rear variants to accomplish specific needs. It’s made as an independent suspension or a beam axle for both setups, with Jeep producing 4WD vehicles that feature the technology at the front and the rear.
Here are the general specs that you’ll find when working with Dana 44 technology.
| Ring Gear Measurement: | 8.5 inches (216mm) |
| OEM Inner Axle Shaft Spline Counts: | 10, 19, 29, 30, 32, 33, and 35 |
| Pinion Shaft Diameter: | 1.375 inches or 1.625 inches (JK model) |
| Pinion Shaft Splines and Diameter: | 26/1.12 inches (After 1970); 24/1.25 inches (JK installations); 10/1.12 inches (Before 1970) |
| Carrier Break: | 2.72:1 to 3.73:1; 3.92:1 to 5.89:1; 6.17:1 (Volvo installations) |
| Gear Ratio Range: | 2.72:1 to 5.89:1 |
| Axle Shaft Diameter: | 1.175 inches (19 Spline) to 1.41 inches (Rear 32 Spline) |
The Dana 44 front axle saw its first use in the 1950s. They were known for their locking hubs and a center axle disconnect system. It’s also not uncommon to see permanently locked-in Dana 44s.
They’re used in quarter-ton, half-ton, three-quarter-ton, and one-ton rated trucks. There are ball joint, closed, open-knuckle, and kingpin variations.
◼️ Why Does the Dana 44A Have a Poor Reputation in Some Circles?
It’s not necessarily the metal composition that generates issues for the Dana 44A. The size and dimensions of the housing are just slightly bigger in all directions, creating more impact areas that might affect its performance compared to the standard Dana 44.
When you put a D44 cover on top of an open D44A, you’ll see that it doesn’t even complete close to lining up. There’s a good 1-2 inches of extra space to cover with the aluminum design, allowing for more open space within the hub.
That’s why few parts from the D44A can interchange with the regular D44 design. The pinion dimensions are different, you have an entirely unique carrier, and it uses C-clip axles.
Get a Box Truss to Maximize Your Dana 44A Housing
When you need an improved strength upgrade for your Dana 44A housing, an axle-boxed truss with internal gusseting is an excellent investment to consider.
The best units provide the structural support needed to run with your setup. Whether you’re putting on 35s or trying something new, this investment works hard to prevent your Dana 44A from bending under severe loads while you’re off-roading.
Although several features and options are variables based on the brand and manufacturer in this category, here are the must-have items that most drivers want for their rides.
- Zero modification setup so that you can start putting on the improvements the moment the shipment arrives.
- Tie-down holes to create more security.
- All the necessary hardware to complete the installation, along with a new brake hard line.
- A snug fit that works between your stock/factory upper control arm mounts.
- Internal gusseting with precision laser cutting and CNC formation to achieve perfect fitment.
- Designs that work with shorter arms while offering mods that allow for longer ones through kits or other means.
When you purchase a box truss for your Dana 44A housing, it helps to verify that fitment for your vehicle before finalizing the transaction. Some products only work on a specific generation of cars, trucks, and SUVs.
If you’re off-roading and your vehicle has a Dana 44A axle, you’re almost committed to this investment before your first trip. Although flat land driving isn’t problematic, one significant bounce could generate enough momentum to create problems.
Why Is the Dana 44 Better Than the Dana 35?
When looking for a 4WD vehicle or something that can handle off-roading conditions, two axle choices come up regularly. You can get the Dana 35 or the Dana 44/44A/44HD.
If you choose the Dana 35, you’ll have a product that works for independent suspensions or fixed axles in a broad ratio range. It handles everything from 3.07:1 to 4.88:1 for the TTB. If you have an IFS, you get ratios of 3.08:1 to 5.13:1.
Any Dana axle has a long history of success. If you opt for the 35, you’ll need to drive responsibly and look after your vehicle. Dropping the clutch or changing gears in the middle of a climb is what often causes problems.
When you compare the D44 to the D35, you’ll have a heavier choice that handles more situations. The Dana 35 is great for general driving and light off-roading, but it has significant weaknesses when you start working it hard. You’ll need to reinforce it, especially since the differential and side shafts are significantly smaller.
As for the Dana 44A, the manufacturer sets them up on the nut at the factory. Once that step gets taken, they press the steel tubes into the center section. This action destroys the carrier bearing preload.
If you catch the axle soon enough, you can replace the carrier bearings. Some people like to remove .006 in shins from both sides to get back to the nut with backlash and preload.
How Much Does It Cost to Repair or Replace an Axle?
If you have an axle problem with your vehicle, the average cost for a repair in the United States is approximately $550 for the front and $800 for the rear. The actual cost depends on your make and model of vehicle, along with whatever additional damage might be part of the problem.
Once the Dana 44A bends, there isn’t much anyone can do to repair the part. It needs to be replaced to avoid having other damage issues occur later during the vehicle’s life. If you’re unsure about the condition of your car right now, there are some symptoms that you’ll experience when driving that indicate this issue might be happening.
1. You have unstable driving conditions.
When the axle shaft of the D44A gets bent, you’ll end up ruining the vehicle’s alignment. That causes the car to pull to one side or create a wobble. It isn’t always easy to spot this issue, but someone driving behind you can see the movement at city speeds.
2. It isn’t quiet when driving.
You’ll get a lot of road noise from some vehicles, such as most Jeep SUVs with off-roading capabilities. When there is a problem with the Dana 44A axle, you’ll hear clicking or clunking noises during operations. This symptom appears because of the friction generation by other vehicle parts and should be checked by a professional right away.
3. The axles are leaking grease.
When you see grease leaking from around your tires, that symptom indicates that the CV joint might have failed. They’re at the end of the axle, near the wheels, and they’ll expel the product when a crack occurs. If you spot this problem, your car needs to be seen for immediate repair.
4. There is more vibration during driving.
When you feel vibrations in the steering wheel while driving, it can indicate that the alignment is off, your axle is bent, or there is an issue with your wheels. If this symptom only occurs while braking, you’ll need to have your pads, rotors, and calipers examined for damage or debris.
Although vibration only feels like a minor inconvenience, failing to take care of it can lead to costly repairs if additional damage occurs.
Is It Safe to Drive on a Bent Axle?
You need the axles for your vehicle to have it function correctly. They work with the transmission to take the engine’s power so that it transfers to the wheels.
Although the Dana 44A is built to last under regular operating conditions, you can cause them to get bent or broken during an accident. Even a simple issue, such as hitting a curb too hard, can create a problem.
Some drivers have even had their axles bend or break while hitting a pothole at highway speeds.
The best practice is to avoid always driving on a bent or broken axle. You don’t want to risk damaging your vehicle.
If you have a slightly bent axle, you’ll experience vibration and rough turning while driving. Repairs are advisable as soon as possible because the bearings, hubs, and CV joints receive more wear and tear in this condition. You’ll want to drive or have the vehicle towed to a collision repair center.
When an axle is severely bent, you cannot drive the vehicle. Anything with damage of more than a quarter inch must get towed to have the part replaced. You can ruin your powertrain by forcing the issue.
A Final Thought About the Dana 44A Strength
I’ve always found the Dana 44A to be a remarkable axle. It has always performed well for me in off-road conditions, including some steep climbs where the vehicle got tested to its limit.
I appreciate the aluminum components because it takes just a touch of the weight off the vehicle. It might not seem like much, but every pound sometimes counts when you’re out there exploring the world!
For me, the way that you treat your vehicle is what unlocks its full potential. I get enough miles to have the oil changed about once per quarter. On every other check, I have my people look at the axles and CV joints to ensure they’re operating correctly.
I would advise that everyone do the same. Although an axle replacement isn’t the most expensive repair, you could still put that money into something else with some proactive maintenance and intelligent driving.
