JANA k4 Installing new sckool JK44s in your old school housing - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 02-17-2011, 12:45 AM   #1 (permalink)
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JANA k4 Installing new sckool JK44s in your old school housing

JANA k4™ kit Installs the new Stronger Dana JK44 gears into your old standard d44 making them approximately 44% stronger. This hybrid kit comes complete with all adapter bearings, standard bearings, seals, shims, spacers & instructions, to install the newer style JK44 gear set with a Dana 44 carrier 3.73 & lower (or Posi) into the old standard pinion D44 housings. Gear ratios available: 4.11, 4.56, 4.88, 5.13, & 5.38. Jana 3/8" thick cover girdles also available.
If you can install ring & pinions & use a die grinder you can install this strength improving kit. If you are running alloy axles then you need this kit as the Ring & Pinion is now the weak link in your drive-train. This kit allows you to upgrade to 31, 32, 33 or 35 spline axles without having the limited strength of the 44 ring and pinion, yet not lose any ground clearance. Questions please email us or call 8-5 Pacific time M-F 360-598-2773 carl@jantzengineering.comName:  Jana K4 with 4.11s.JPG
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Basic kit is pictured here with a 1350 Pinion yoke. 1310 yokes are also available.
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The Newer JK44 Pinion shaft is the same diameter as a Dana 60 it uses a unique 1 5/16" 24 spline shaft requiring a new yoke supplied in the kit. Here are the 1350 & 1310 series yokes. Name:  JK yokes sm.jpg
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How its Done
1st, we have to get the larger gear in the housing. Since the Jk44 ring gear is approximately 1/2" larger in diameter the than the D44 ring gear there needs to be 1/4" clearance around the D44 ring gear in the housing to clear it, most 44 housings are cast with approximately 3/16" clearance, so only very small amount of grinding in a few spots is necessary.

2nd, we have to get the pinion in, and it needs different bearings to accommodate the larger shaft size. luckily there is room to get the parts in with the proper spacers, shims and adapter rings.

3rd, The larger and thicker ring gear needs a carrier that moves the ring gear away from the pinion. To do this a D44 3.73 & lower numerically carrier is used. So even though you are installing 4.11 series & up numerically you need the 3.73 & down numerically carrier to get the ring gear flange farther away from the pinion center line.The carrier is also drilled to accept the larger JK44 ring gear bolts.

Update:
If you have found this thread you will be very interested in these threads which deal with each hybrid in our product line specifically;

HOW TO Install
Load Bolts into Stock housings:/forum/axles-tires-wheels/1059807-load-bolts-how-install-yourself.html
D50s into HPD44's, Jana 54:http://pirate4x4.com/forum/showthread.php?t=948996
D70s into D60s, Jana 76:http://pirate4x4.com/forum/showthread.php?t=946421
D80s into D70's Jana 87: http://pirate4x4.com/forum/showthread.php?t=958266
Holding it all together, Jana cover girdles:http://pirate4x4.com/forum/showthread.php?t=958047
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Old 02-17-2011, 01:01 AM   #2 (permalink)
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Cost Benefit Analysis

Cost Benefit Analysis
1st the Benefits,

Your Ring & Pinion is 44% stronger! with no loss of ground clearance.
Dana rates the 44 @ 3460 Ft-lbs maximum momentary output torque.
Although I could not get exact figures from Dana the pictures show that the JK44 gears are beefier than a D50 set and since Dana rates the 50 @ 5000 Ft-lbs maximum momentary output torque.
Your going to get more than 1500 ft-lb increase in capacity.
Also if you have alloy axles, then your current week link is the most difficult and expensive part to repair ie, the ring & pinion. Lets not have that.

2nd the Cost,

The net cost is only $150 bucks, and a few more minutes labor.
If you compare the cost of the new school gears to the old school gears they are within a few bucks of each other. Now if your gonna do this right then you need a new installation and bearing kit as well, this is gonna set ya back about $150. Your gonna buy a posi/ locker anyway so that doesn't even figure in.

The cost of a Jana K4 kit is approximately $300* (most kits, subject to change).
Thus net cost around $150.
Folks, this is a No brainer

*May also purchase, Axle tube seals, HD yokes, & Jana cover girdle (more on this later)

For comparison purposes all these gears sets are 4.11s.
The teeth on the JKs are a 1/4" longer, curvier, and angled more than the others enlarging the contact area between the gears thus lowering the stress concentrations.

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Old 02-17-2011, 01:03 AM   #3 (permalink)
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Rounding up parts

We of course can sell you everything necessary for this hybrid conversion. But there are also plenty of wrecking yard finds for the cost conscious.
The question I get the most is " What carrier do I need to find to work with this Hybrid kit?" The answer is any 44 carrier/posi/locker that is made for 3.73 & down numerically gears. (sometimes referred to as a High speed carrier). The next question I get is "I already have a D44 3.92 & up carrier/posi/locker, can it be made to fit?" Unfortunately the answer is typically no. However If you have a ARB air locker we can supply you with a new case 1/2 and air cap assembly so you can put your internals in it. There are also the new Jeep Rubicon & JK OEM factory air lockers that will fit.
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Old 02-17-2011, 01:22 AM   #4 (permalink)
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Holding it all together

When you ask your gears to do more you are also asking you housing to do more, several after market suppliers have upgrades such as 4340 billet bearing caps, and aluminum covers with load bolts to keep the carrier caps from defecting under extreme pressure, and Even Toyota is using a one piece carrier cap girdle that hoops over the ring gear to prevent the caps from spreading. So since you need that bullet proof cover to protect your investment from rock damage you might as well have it prevent housing defection as well. Our covers incorporate both the load bolt and the cap girdle in one unit. I can also do this to your existing cover if you have already invested in a HD unit. For more info please follow this link: http://pirate4x4.com/forum/showthread.php?t=958047
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Old 02-17-2011, 02:35 AM   #5 (permalink)
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Some hope for the LP guys, I like it! As soon as I can get mine out on the trail and initial bugs worked out, this certainly is the path i'll be taking. Thanks!
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Old 02-18-2011, 12:35 AM   #6 (permalink)
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Pricing

$270 Jana K4 Base kit*

Options:

$36 Pair of carrier bearings (stock type bearings) or $50 some aftermarket carrier brgs
$50 Upgrade to 1350 yoke (base kit comes with 1310)
$225 cover Girdle
$45 (3) qt. Severe gear 250
$232 Ring & pinions: 4.10s 4.88s, 5.13, 5.38 ($253 4.56)
$25 pair of inner axle seals 30 & 33 spline ($20 for 35 spline)
$30 Pinion head set up bearing race

* Base kit now comes standard with solid preload spacer & shims. (no crush sleeves).

Note: prices do not include shipping or tax and are subject to change.

We will meet or beat Randy's online pricing for Lockers.
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Old 02-21-2011, 05:35 AM   #7 (permalink)
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Hi Carl, great infos on your kits here!
Do you ship to europe?
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Old 02-21-2011, 06:18 AM   #8 (permalink)
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To the heart of the Alps

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Originally Posted by jeeptomster View Post
Hi Carl, great infos on your kits here!
Do you ship to europe?
I've shipped to Guam and & Canada, I'll figure it out. What are you working on.?
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Old 03-04-2011, 03:35 PM   #9 (permalink)
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How much is the ARB adapter?
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Old 04-04-2011, 09:51 PM   #10 (permalink)
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Question

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Originally Posted by unRL View Post
$240 Jana K4 Base kit

Options:

$36 Pair of carrier bearings
$40 Upgrade to 1350 yoke (base kit comes with 1310)
$225 cover Girdle
$45 (3) qt. Severe gear 250
$210 Ring & pinion: 4.88s, 5.13, 5.38 ($253 4.56)
$25 pair of inner axle seals 30 & 33 spline ($20 for 35 spline)
$40 Pinion head set up bearing
$13 Upgrade to solid pinion preload spacer & shims (kit comes with crush sleeves)

Note: prices do not include shipping or tax and are subject to change.

We will meet or beat Randy's online pricing for Lockers.
Any reason I couldn't use 4.27s?
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Old 04-05-2011, 12:36 AM   #11 (permalink)
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Quote:
Originally Posted by OCNORB View Post
Any reason I couldn't use 4.27s?
thank you, I did not realize 4.27s were available, where did you find them?
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Old 04-16-2011, 05:41 PM   #12 (permalink)
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Honda Passport rear

Have you tried putting one of these kits in a Honda Passport rear? I just picked one of these up and have heard the pinion bearing is larger.
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Old 04-18-2011, 02:32 PM   #13 (permalink)
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Smile Passports & Rodeo's

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Originally Posted by 92Trailrunner View Post
Have you tried putting one of these kits in a Honda Passport rear? I just picked one of these up and have heard the pinion bearing is larger.
Ok so understanding that 93 and up and they were used on both the Honda Passports and Isuzu Rodeos, along with some years of Nissan Titans, I just need to know what bearings they used to do some calculating, For the correct bearing / spacer combo for pinion depth,
Then (as you said in your PM) the thing that would really work for These applications is from the factory they use thick cut gears so even if the axle has 4.10's 4.30's or 4.56's & up the carrier is a 3.73 and numerically lower carrier.) So it can take the thicker JK gears without needing to swap to a different carrier or locker.
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Old 04-23-2011, 04:11 AM   #14 (permalink)
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strength with 40's

Karl do you think the k4 setup would withstand 40'' goodyears on a tj. I am wanting to run 40's but I want to save weight as much as possible. What would be my weak link if I were to run wagoneer front 44 with a passport rear with your set up. For know it would have stock engine/trans/transfercase. What lockers are available in 35 spline.
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Old 04-23-2011, 09:13 AM   #15 (permalink)
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Quote:
Originally Posted by krawlin5 View Post
Karl do you think the k4 setup would withstand 40'' goodyears on a tj. I am wanting to run 40's but I want to save weight as much as possible. What would be my weak link if I were to run wagoneer front 44 with a passport rear with your set up. For know it would have stock engine/trans/transfercase. What lockers are available in 35 spline.
I've given this considerable thought. Yes you can get a 35 spline Air Locker for the 44. But if you go 35 spline axles the ring & pinion is the weak link once again. 40" tires if caught between a rock and hard place can break 60 parts. However I've seen plenty of 40s on stock d44 as long as you drive them accordingly. But eventually something snaps, so you are looking for a reasonably long lasting solution that will not break the bank. Here is my Professional recommendation.
Run 33 spline inner axles that are comp cut* & 19 spline outer axles with Super Joints. Carry a spare outer axle. This makes you a weak link that is trail manageable. The comp cut axles will allow some torsional flex in the system such that your gears, hubs, & U-joints do not see the shock loads seen with thick axles thus preventing lots of fatigue. I would not run 30 spline outer for the following reason, If they snap inside the spindle there is no room for them to break and they will destroy your wheel bearings as the axle parts expand. (Been there done it 5 times)
*Comp Cutting or Wasted diameter axles work like this, Just as a bolt is no stronger than the root diameter of the threads an axle is no stronger than the root diameter of the splines. So an axle reduced to the root diameter is just as strong as a thick axle yet it will wind up along its length instead of snap at the spline. For more on this please review this thread:http://pirate4x4.com/forum/showthread.php?t=917868
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Old 04-23-2011, 11:10 AM   #16 (permalink)
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Thanks for the reply. I am considering this a option because of the limit availblity of ford dana 60,s in my area. Also I think that with the weight savings less likely to brake parts. I would eventualy run a stock ls engine at some point but I dont want to do more work later on down the road. Where do you get your comp axles. And also I guess it would be a bad idea to use the Dana 50 knuckles for the larger shafts as the ring and pinion would be the fuse. Again thanks for the info.
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Old 04-23-2011, 12:28 PM   #17 (permalink)
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Quote:
Originally Posted by krawlin5 View Post
Where do you get your comp axles.
I would be happy to make them for you.
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Old 04-23-2011, 04:31 PM   #18 (permalink)
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Karl are you buying blanks and if so who from, and how much. Also is a 5.38 gear set available for both waggy 44 and passport 44.
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Old 05-13-2011, 12:11 AM   #19 (permalink)
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Would there need to be machining for a 35 spline ARB with this different gear set? I know I saw something about that in the HP44 w/50 gears thread, don't know if it applies here as well.

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Old 05-13-2011, 12:15 PM   #20 (permalink)
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Quote:
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Would there need to be machining for a 35 spline ARB with this different gear set? I know I saw something about that in the HP44 w/50 gears thread, don't know if it applies here as well.
No machining required, however, you will have to drill the ring gear bolt holes size la
rger.
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Old 05-13-2011, 02:05 PM   #21 (permalink)
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No machining required, however, you will have to drill the ring gear bolt holes size la
rger.
That's what I needed to know, thanks!
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Old 07-31-2011, 04:33 PM   #22 (permalink)
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Can you use this kit for both lp and hp configurations? If so, what would you recommend more in the front hp application, d50 or jk d44 gears?
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Old 08-01-2011, 01:39 AM   #23 (permalink)
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Need to regear by TJ RUBI axles. Would it be to my advantage to run JK gears? If so can you please provide a quote or 513s and your kit. Thanks
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Old 09-30-2011, 08:50 AM   #24 (permalink)
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bearings

so, if you put a larger pinion into the same housing, there is now less room for the bearings. Is there any strength or durability issues with the new pinion bearings??? Are the stud-girdles a necessity, or just nice to have? I am regearing an older 44 and just found out about this new option.

Also, what is the cost for the bearing/install kit with a 1310 yoke?

Last edited by strange1; 09-30-2011 at 08:52 AM.
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Old 10-01-2011, 01:53 AM   #25 (permalink)
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Quote:
Originally Posted by strange1 View Post
so, if you put a larger pinion into the same housing, there is now less room for the bearings. Is there any strength or durability issues with the new pinion bearings??? Are the stud-girdles a necessity, or just nice to have? I am regearing an older 44 and just found out about this new option.

Also, what is the cost for the bearing/install kit with a 1310 yoke?
Good questions, Thanks for asking.
The stock 44 pinion head bearing has a load rating of 19,700 lbf.*
The Jana K4 head bearing is rated 19,700 lbf. Only 3.5% weaker. So considering that you rarely see pinion bearing failures in stock 44s even when the pinion breaks I'd say we are in the safe range. Also considering that a Dana 50 pinion head bearing is only rated at 16,000 lbf I would conclude the 44 is well over designed in this case. Now on to the Pinion tail bearing, I actually use a wider bearing in the rear rated at 18,700 lbf compared to the stock 44 at only 13,700 lbf.
Now think the following over: A rear Low pinion gear set pushes the ring gear around thus the main thrust is on the head bearing. Conversely, a front low pinion pulls the ring gear around thus the main thrust load is taken up by the tail bearing, so in a front end the Jana K4 is way a head on bearing capacity.
As for cover girdles, if you look at any consistent drag racer they are using covers designed with Jack Bolts in them to prevent cap failure, and many after market companies supply them. 4 wheeling puts way more stress on housings than most drag cars, so the Girdles are not only the Icing on the cake but a good way of extending the life of your investment.
For pricing check out Post #6, and the prices were recently updated.
*Dynamic Radial Load Rating - 1 M revs Pounds Force Per Timken Web Site.
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