THE Definative Tech Thread on the 1998+ Isuzu rear Dana 44 axle - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 08-08-2007, 11:32 AM   #1 (permalink)
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THE Definative Tech Thread on the 1998+ Isuzu rear Dana 44 axle

just like the title says....the purpose here is to clear all the confusion and speculative tech (or just plain incorrect tech ) abouth the rear Dana 44 axle Isuzu started using in 1998 in the 2nd Gen Rodeo/amigo/rodeo sport platform.

for this write up i will be using a 2002 Rodeo Rear.

we will be illustrating what it actuallly takes to swap a "standard" Dana 44 ring and Pinion into this "modified" housing.

we will be swapping out factory 4.30's for Yukon 5.13's.

Also, in this particular build we will be swapping otut he factory trak-lock rear diff for an open carrier and an Aussie Locker.
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Old 08-09-2007, 06:55 PM   #2 (permalink)
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ok.

i get a few calls a week with ??'s on gear swaps for 1998 and newer Rodeos and Amigos and i want to clear the air w/ some real tech on what's up w/ these axles and why you (until now) cannot just simply swap in a "regular" D44 gear.

so let's start w/ what this axle IS.....then we wil move on to what you CAN do (in terms of variations on swap options.the)


this axle DOES NOT have a regular Dana Spicer 44 gear. But we will get to that. First let's get a little background tech:



1. there are factory gear's available. ratios include the most common 4.10 & 4.30 options found in most all of these trucks w/ factory v-6 motors.

2. there are factory 4.77 Dana Spicer gears availabe for these - originally optioned in the 1998-99 trucks w/ the 4cyl. Motor. these can be purchased from Isuzu Direct ...... sold as a "kit" with ring gear bolts and a Pinion nut.

3. MOST ALL of these years have a Dana Spicer Limited slip ....called a Trac-Loc. Althought the word "Lock" is in the name these are in NO WAY a LOCKER. tHis is a super common limited slip using friction disks betweeh each side gear and the carrier. The Spicer Trac-Lock is a less aggressive, street-friendly limited slip suitable for daily driven vehicles and mild off-road use.....thus it is an OEM diff in many vehicles. This unit uses clutch packs and is Rebuildable.

these actually look alot like open carriers and are often mistaken:





4. this leads us to swapping this factory unit for something more aggressive.
the typical choice is the Powertrax No-slip as it fits in the typical Trac-lock carrier.



this unit replaces the spider and side gears in the existing carrier.

5. Full carrier lockers - you can run any full carrier locker in this Isuzu rear D44 but, remember you will need to use the oppropriate carrier. meaning: w/ factory ratios (althoght 4.10, 4.30, 4.77) you actually need a 3.73 & down (numerically lower) carrier. This is due to the Thick ring gear Isuzu used in these axles.




ok.............moving on to the actual factory gear vs. the standard D44 gear.
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Old 08-13-2007, 08:24 AM   #3 (permalink)
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just for reference......here is the stock diff w/ Trac-lok. note the thicker than normal ring gear. this is a 4.30 on a 3.73 & down carrier:
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Old 08-13-2007, 08:25 AM   #4 (permalink)
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Old 08-13-2007, 08:29 AM   #5 (permalink)
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here is the comparison of the ring & pinions out of the housing. Factory Isuzu thick on the left, stock Dana spicer 5.13 on the right. Take note of the larger pinion on the gear on the left.


also as you can see int he pic, the Isuzu gear is a crush sleeve design, the pinion we will be using is a shimmed design.
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Old 08-13-2007, 08:34 AM   #6 (permalink)
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note that with the crush sleeve collar in place the two pinions are basically the same ......... at least they are within a reasonable tolerance to ship.

side by side...... so far so good.
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Old 08-13-2007, 08:36 AM   #7 (permalink)
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overall pinion shaft length is the same...........although the new pinion is a smaller diameter. in this pic, cruch collar is removed to show the differences in surface for the outter pinion bearing (small bearing):
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Old 08-13-2007, 08:45 AM   #8 (permalink)
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ok, so now that we have established that the pinion lenght will interchange and our new pinion will work in "that" dimension, we move on to the shaft diameter.

this pic shows a comparison of the pinion bearing surface I.D.'s

a standard Dana 44 pinion is 1.125" on the outer, and 1.375" on th larger inner bearing.


the Isuzu Pinion is 1.312" & 1.625" ......... so here's where we run into an Issue you cannot just swap in a reg, gear and install kit. now we need to do some homework on crossover bearings. That is........a bearing with the same I.D. as the standard pinion, but with an O.D. that will allow us to press the race in the Isuzu Housing.
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Old 08-13-2007, 08:50 AM   #9 (permalink)
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this pic makes it a little easier to tell.......the splines for the yoke as well as the pinion nut diameter are also much larger.

this looked familiar i immediately recognized this to be the same as a Dana 60 (same way that the rear aluminum D44 in the Jeep Grand - ZJ has a D60 Yoke):
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Old 08-13-2007, 08:57 AM   #10 (permalink)
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so....of course we need a comparison shot..... left to right - standard D44, Isuzu D44 1998+, Dana 60..........

D60 is a larger & longer pinion, but the measurements of the yoke splines and nut are the same as the Isuzu D44.

for comparison, the D60 inner (large) bearing I.D. is 1.750" but the outter (small) bearing I.D. is actually Smaller than Isuzu @ only 1.250"
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Old 08-13-2007, 09:11 AM   #11 (permalink)
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and YES ......i know you were wondering..............the Isuzu Yoke DOES fit the Dana 60 like a glove

so when it's time to swap a D60 in your rig you can use your stock shafts and a 1998+ Isuzu pinion Yoke:
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Old 08-13-2007, 04:48 PM   #12 (permalink)
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Good info, Matt... keep it coming
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Old 08-14-2007, 07:00 PM   #13 (permalink)
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on the housing:

the OEM seal is the same I.D. as a D60..........buy the housing O.D. is the same for a standard D44 seal......so the swap continues.

tomm i will post comp. pics of the LSD carrier and the open carrier.
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Old 08-15-2007, 07:22 AM   #14 (permalink)
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wow, I can't believe how beefy that isuzu pinion is! Awesome info man.
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Old 08-23-2007, 08:26 PM   #15 (permalink)
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Thats sweet stuff Matt you should put this in the FAQ thread if you get a chance. It seems like we get a lot of posts about this maybe it will save a few of the repeat questions
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Old 08-24-2007, 06:44 AM   #16 (permalink)
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certianly not done yet.....i'll get back on this next week....got a lot going on in the shop right now.
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Old 10-04-2007, 07:10 PM   #17 (permalink)
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so...mission accomplished.

we have successfully completed the install of a standard Dana 44 Ring and pinion into the 1998+ Isuzu rear Dana 44 housing.

out of this...................i am very excited to say a couple of new options are opened up

I now have a Full master install kit SPECIFICALLY for this housing.

We will now offer re-gear kits for the 98+ rodeo/amigos in 4.56 gears...to replace the 4.10's and 4.30's from the factory.


so....guess i'll post up the installation and show you guys the new product 1st.

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Old 10-04-2007, 08:13 PM   #18 (permalink)
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Nice work Matt

That opens up a lot of options
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Old 11-26-2007, 04:31 PM   #19 (permalink)
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Old 11-26-2007, 04:53 PM   #20 (permalink)
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thanks i hadn't forgotten.....just got really busy.


i'll finish this up
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Old 11-26-2007, 06:08 PM   #21 (permalink)
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So here's where all the tech went.....Isuzu section....who knew?
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Old 11-28-2007, 07:08 AM   #22 (permalink)
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We will now offer re-gear kits for the 98+ rodeo/amigos in 4.56 gears
Matt-What about 5.38's??

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Old 11-28-2007, 05:08 PM   #23 (permalink)
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Originally Posted by TrooperRS View Post
...so when it's time to swap a D60 in your rig you can use your stock shafts and a 1998+ Isuzu pinion Yoke:
That's worth a beer, right there, Matt!

Collect in Moab!

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Old 11-30-2007, 08:47 AM   #24 (permalink)
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oh yeah, i forgot to mention that to you Randii........i did actually think of you as i was putting that yoke on the D60 pinion.

i now have pics of the fianl install kits


need to re-up my yeller star to post the rest o' the pics

-matt
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Old 01-06-2008, 02:18 PM   #25 (permalink)
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Question Rodeo gears in other dana 44

Newbe here. Thanks for the information Independent4x.

Question: Can I use the Rodeo Dana 44 small carrier and wide 4.30 gears in a Jeep J10 pickup with existing Dana 44 diff's front and rear?

Thanks in advance.
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