91coMANche

Factory could have worked with the Dana 44. Once under there my new grade 8 u-bolts worked perfectly. Axles in, driveshafts in, and weight sensing valve is ready to hooked up but not before i pull the cover to reseal and refill some 80W-90. If only I had a posi!

Oh man! I just got my Dana 44 in and will be bleeding in a bit! Thanks for the heads up! Can you clarify how to rebleed the rear with the front bleeder open? If I understand correctly I bleed the entire truck. Then open a front bleeder and push the pedal to the floor...do I think close the bleeder before releasing the pedal? Now you say to bleed the rear with the front open...wouldn't that allow air into the front? Once I bleed with the front open, do I close the front and rebleed the rear?

Just got the 35 out. The new U-bolts seem to be exactly the same size as the ones I pulled off the 35. 2.75" tubes on the 44 and maybe the 91 Dana 35? I know later Dana 35's had 44 sized tubes. Perhaps the C-clip 35 uses the same tube?

Thanks Don. I didn't buy the Dorman ones because I found out they are Chinese. So I went to the spring shop near the driveshaft shop that shorted my shaft and had some 2.75X8X9/16" grade 8 bolts bent along with grade 8 hi-nuts and grade 8 thick washers. $60 for the set but well worth it to first off support :USAflag: and consequently get a quality product.

These are 1/2" thick, 2 7/8" axle opening, 8 inches long.

Well Dorman makes ubolts in the size I posted BUT not in 2.75". Let see if anyone can confirm fitment.

Like everybody has said: get a good used one. Rebuilding an AW4 is redundant. You can easily negotiate a good deal on an AW4 as long as you don't rush.

So I ordered some U-Bolts to arrive tomorrow. They only have 2 7/8" U-bolts. Will that work with an MJ 44 or do I need to get some made in 2.75" (possible but a far drive compared to what the parts store is getting me by tomorrow). Just want to know before I take apart the manche tonight.

So the Carquest only has 2 7/8" x 1/2" x 8" u-bolts. Will 2 7/8" work with my D44 or will it be too big?

I don't think there are any aftermarket parts available.

Why is that they only rub on one side? Always wondered... Never put much thought into it though. Rob L. Because we have the trackbar pulling to one side. Either you don't lift it enough and it rubs on one side or you have sagging and the suspension droops to the other side. You will always have rubbing on one side unless you are super vigilant with trackbar adjustment to compensate for suspension height when installed, loaded, and finally settled/sagged.

What size hole is drilled through the axle for the end of the swaybar link to mount through? The holes I am referencing are the only two holes on the axle, which have a swaybar link bolted to them.

I've known a few people with failed cams once they upgraded. It could have been a bad manufacturers batch, the details of which I am unsure. Generally speaking, the 4.0 in factory displacement and build is an ideal engine.

Whats the transmission doing? Tough to kill an AW4.

Sounds good thanks folks. I will get 1/2" U-bolts then.

I was in your shoes but instead bought a ZJ 4.0. They live easy lives behind an automatic and you can get them for $300-$500 with around 100K on them. The 96-99 engines swap in and have everything upgraded including block/piston/rings. I would just grab a modern 4.0 and enjoy the power. Also the modern 4.0 has a block casting that reduces lots of noise.

Eeek. Unless you've done windshields forget it. Removal usually breaks the windshield. I would call safelite or another windshield place. The XJ is so common that the glass is really cheap new and installed. By the time you buy the windshield, gas to get to yard, glue, and suction cups to install you would be way over having a mobile guy come to your house.

Why thank you. :brows: :brows: :brows: :brows: :brows: The tires on my Jeep are load range E, I keep em aired up at about 60 PSI. Unless you're carrying around blocks of lead you are going to wear out the center of your tires quick I feel...right?

I can reuse the Dana 35 ones? I don't have Dana 44 ones from the parts MJ.

That seems like its going to have a scary outcome...

No problem. Its probably best if you just pull the motor and measure when you are ready to do the swap.

A brother truck.

I am gearing up to put my Dana 44 in my 1991. I know I'll need some new 2.75x8x9/16 U-bolts and to have my driveshaft shortened 1". What I need to know now is whether I will need to source new spring plates?

rockauto.com

As long as you're 100% positive you have a 92 and not a late 91 4.0 then you would use either of these OEM bushings: 53009180AB or 53009181. I may have them laying around from my swap.