Dana 44 Front Project

This project actually contains more than just a Dana 44 front axle.  The axle is going to be built by Tri County and it's going to have High Steer knuckles, Warn locking hubs, 4.88 gears and an ARB.  To get this axle functional on my Jeep I have to re-gear the rear axle to 4.88, change the rear axle bolt pattern to 5x5.5, change the bolt pattern on the spare tire carrier and buy new wheels.

07/26/2000 - Ordered axle
I ordered my new axle from Jason Bunch at Tri-County gear.  He's giving me an estimate of 1 month to have it complete.  I let him know I'd really like it a little sooner than that because I have a trip planned around that time.

I called Champion Wheel to order 5 Baja Bead Lock wheels (15x10 5x5.5").  He said he doesn't have any right now and to call back on Monday to find out when he will have them.

07/28/2000 - Trying to find tires,  Measured front axle at Tri-County
I called 4 Wheel Parts Wholesalers to buy 5 Super Swamper SSR's but they are out of stock on 35"x12.5"x15".  They suggested I call back at the end of next week.

I trailered the Jeep to Tri-County and had Jason measure the front suspension for the new axle.  I talked to him again about the 1 month lead time and let him know it would really help me out if he could build the axle in 2 or 3 weeks.

07/31/2000 - Wheels, wheels, wheels
I called Champion to ask when he will have more Baja Bead Lock wheels for sale.  He said he has no idea.  He suggested I call back once a week to find out when he has some.  Personally I think that's poor business practices considering I'm ready to spend the money.  I would expect a company to at least take my name and number and give me a call when he has them.  Instead, I drove to Barney's Wheel and Tire in Temecula.  He said he can get me 5 American Racing Baja 15x10 on 5x5.5" and have them shipped to Champion.  Then Champion can do the bead locks and send them to me.  I paid Barney and sent a fax to Champion letting them know that the wheels are coming and what to do with them.  I asked them, on the fax, to call me and confirm they know what to do but they did not call.

08/01/2000 - Removed rear axle
I removed the rear axle and cleaned it up.  I'll be dropping it off at Tri County on Thursday to have it re-geared and re-lugged.  I discovered that my rear u-bolts and u-bolt plates are not the correct size.  They were a real pain in the butt to remove.  I'll get some proper sized ones from Tri-County.

I also started work on my spare tire carrier.  The spare tire mounts on three bolts.  I left the bottom bolt in the original location and I re-drilled two new holes for the lugs to be moved to.  I have to pick up a couple nuts at the hardware store to weld to the back plate.

08/02/2000 - Spare tire carrier
I finished re-lugging the spare tire carrier.  It now holds a 5x5.5" wheel and the tire will be 1" higher (Hey Brian) .  I also called Champion and left a voice message asking them to call me back.  I'm confused because the answering machine message says he's just out of the office "for a few".  I wonder if he meant a few days...

08/03/2000 - Found Tires, still no call from Champion
Called 4 Wheel Parts Wholesalers again.  They have tires now.  I'll be stopping by their store on Monday to pick up 5 Super Swamper SSR's (35x12.5x15).  I called Champion again and still I only got the answering machine.  I'm getting a little nervous since I had my new Baja's shipped directly to his store.  Is anyone there to receive them?

I dropped off my rear Dana 44 at Tri County Gear to have the gears changed to 4.88 and to have the axles re-lugged to 5x5.5".  I tried to talk to Jason to find out when they think my axles will be done but he was too busy.  Hmm, what ever happened to customer service?

08/07/2000 - Picked up the tires
I picked up the tires from 4 Wheel Parts Wholesalers.  I'm not sure I got "wholesale" pricing, but I did save a few bucks.

08/08/2000 - Axle status, Wheel status
I called Tri-County to see if they can give me a date for when the axle work will be complete.  Dennis called me back and said that they were working on the front axle today!  Dennis also said that there is a problem with the ARB in my rear axle that I dropped off last Thursday evening.  He said he'll have to order a new "top cap".  He'll call me back with exact pricing.

I also called Champion Wheel to see if I can talk to ANYONE there.  I still only get the answering machine.

08/09/2000 - Wheels
I tried calling Champion again but still no one answers the phone.  I also called Barney's Wheel & Tire to start tracking the wheels that shipped.  I need to at least find out if the shipment was returned to American Racing or if they were received at Champion.

UPS says that the wheels were dropped off "At the garage" on Aug 3.  I wonder if they've been sitting there ever since, or did someone at Champion at least take them inside.

Dennis at Tri County Gear said that my front axle is done.  He ordered a new "Top Cap" for the ARB in my rear axle.  The axles should be ready to be picked up next week.

08/10/2000 - Champion answered the phone!
The guy at Champion said that he's been so busy lately that he's been ignoring the phone.  He said that my wheels should be done sometime next week.  The timing should work out good since my axles are also due to be done next week.

08/13/2000 - Front Dana 30 removed
I removed the Dana 30 front axle today.  I removed the 4.56 gears, Lock-Rite locker and Rancho brake pads so friends could use them.  I still have to remove the dropped pitman arm.  That's never a fun task.

08/15/2000 - Not done!
I called Tri County to see when I should pick up my axles this week.  Turns out that the front axle is NOT done yet.  Last Wednesday I was told that the front was completely done and they were waiting on parts for the rear axle.  Today they are saying that the knuckles just arrived for the front axle and they will complete it early NEXT week.

I also called Champion Wheel.  Last Wednesday they told me the wheels will be done this week.  NOT!  They are saying "next week", just like Tri County.  We have a trip planned over Labor Day weekend.  I can't afford another "next week" comment.

Later in the day I called Champion and let them know they are jeopardizing my trip that I have planned because they are taking so long with my wheels.  I told them that I really need them to chip my wheels back to me this Friday.  They asked me to write all the information down and fax it to them.  HE said he will move my wheels to the front of the line and do his best to get them done by Friday.

08/16/2000 - Tri County status
I called Tri County and spoke to Dennis.  I told him I need to be able to pick up my axles this Friday.  He said he is waiting on the "Top Cap" for the rear axle and they are waiting on brake rotors for the front axle.  As soon as those parts arrive he'll get the axles done ASAP.  I did not get the confirmation that the axles will be ready by Friday like I wanted.

08/17/2000 - Getting Closer
I called Tri County and spoke to Dennis.  He said that the front axle should be ready for pickup tomorrow afternoon.  He also said the "Top Cap" has not arrived via UPS yet, but he'll borrow a "Top Cap" from another ARB for mine if mine doesn't arrive in time.

I also called Champion and he said they are on schedule to ship the wheels Friday.  I should see them Tuesday or Wednesday next week.

08/18/2000 - Possible rear axle problem
Jason from Tri County left a message for me last night.  He said that there's a problem with my rear axle.  I called Jason back and he said that it's the "Top Cap" problem.  He didn't know that Dennis and I have been talking about it for a week.  I told him that Dennis ordered the Top Cap and if it doesn't come in on time, he'll borrow a Top Cap from another ARB to have my axle ready for me to pick up.  Jason said he doesn't like to do that and I'll have to wait for the Top Cap to arrive from ARB.  I said that was not acceptable.  I got Dennis on the phone and told him what was going on.  I told him that I will be at their shop at 1pm today to pick up my axles.  He said "No problem, I'll take care of it.  The axles will be ready".

A little later Jason called me and said "What's this about re-lugging your rear axle?"  I confirmed what is written on the order that I want the axle re-lugged to 5x5.5".  He said he can't finish it by 1pm.  I asked when he can have it done and he said he'd get back to me.  When he called back he said it'll be ready at 3pm.

Champion said that they will be shipping my wheels today.  Should see them Tuesday or Wednesday next week.

It's too bad these companies require a daily "nagging" phone call and constant harassment for them to do what they advertise and promise.

I arrived at Tri County right at 3pm.  What do you know, my stuff wasn't ready to go.  My rear axle was done and ready but they still had not bored out a pitman arm for me.  While they were doing that they loaded up the axles on my trailer and I paid the bill.  While I was waiting for the pitman arm I was looking at the spring perches on the new front axle and they just didn't look right.  The perch was almost perpendicular to the ball joints.  With the angle on my leaf springs from the reverse shackle, this would give me about 15 positive caster.  I grabbed Dennis and told him we needed to double check the perch angles.  He grabbed Jason and we confirmed that the perches were set at a standard SOA angle.  I removed the tie down straps and they took the axle back into the shop.  It took about an hour, but they fixed the perch angles and loaded up the axle on the trailer again.  We left for home at exactly 6pm.

08/19/2000 - Installed axles
I started with the rear axle.  I put it in place and bolted it up.  I was going to use new U-bolts and U-bolt plates, but I decided to keep my U-bolt plates since they already have the traction arm mount that I need.  Also, the U-bolts that I got from Tri-County were about 4 inches too long.  I didn't see any reason to install these bolts just to have to cut them later.

Then I installed the front axle.  I had to drill out the brake line hoses 1/16th inch to mount to the new calipers.  To do this I had a helper hold an air nozzle to the other end of the hose and constantly apply air pressure while I was drilling on the press.  This ensured that no metal shavings made their way back into the hose.  After changing the pitman arm to the stock, bored out arm, I installed the connecting arm (aka tie-rod).  I couldn't get the drag link installed because the pitman arm hit the connecting arm.  I had to remove the axle, remove the  top leaf spring and drill a new hole 1 inch back to move the axle back.  After doing that, the drag link was installed.  The ball joint on the drag link (the one that connects to the connecting arm) hits the leaf spring though.  I'll have to heat up the connecting arm and twist it to get the ball joint higher.

08/20/2000 - Test drive
I finished hooking up the little things like the drive-shaft, wired up the ARB switch, ran the ARB hose, bled the brakes and installed Darrin's tires.  Then I took the Jeep for a test drive.  The sway bar is not connected yet so it's not what I'm use to in the street.  It seems there's more caster than there was before.  I tested the front ARB locker and it locked up solid.  After I put the Jeep back in the garage, I put it on jack stands and gave Darrin his tires back.  My wheels are due to arrive to my house Tuesday or Wednesday this week.

08/21/2000 - Rude people at Champion Wheels
I called Champion to confirm that my wheels shipped out last Friday.  He said "You bet, they are on the way."  He then he abruptly hung up the phone.  I guess he got tired of my daily phone calls.  If they truly are on the way, at least I don't have to call there anymore.

My wheels arrived today!  Wanna see a picture? UPS ground delivered in two days.  After work I installed the valve stems, installed the tires, bolted the rings, aired them up and installed them on the Jeep.  I then modified the connecting arm to give the drag link ball joint more room over the leaf spring.  I think it's still going to hit, but just when the tire is completely drooped.  I then used the torch to cut the front upper track arm mount from the frame.  When the drivers side front wheel compresses into the fender, the connecting arm would have come in contact with the track arm mount.  Since I don't need that track arm mount anymore I removed it.

08/22/2000 - Drive shaft and wheel balance
This morning I dropped the front drive shaft at the local driveline shop to have it shortened and balanced.  They're going take 3 inches off.  After work I took the Jeep to Americas Tire to have the tires balanced.  Super Swampers don't balance very nice.  Took a lot of weight.

08/23/2000 - Installed drive shaft
All I did today was install the front drive shaft.

08/24/2000 - Sway bar connections, Alignment problems
Today I cut the sway bar mounts off the original U-bolt plates and I welded them to the new U-bolt plates.  Then I installed the quick disconnects and connected the sway bar.

I also tried to get the front wheels aligned.  I thought that the upper ball joints on my new fancy axle gave me the ability to adjust camber.  Especially since the tires are so obviously off-camber.  Well, it's not adjustable, which means that Tri-County built it crooked.  This is just going to add to the cost of the axle because I now have to throw away the brand new upper ball joints and install adjustable ones.  After the Dusy/Ershim trip I'll be calling Tri-County and discussing some sort of re-imbursement.  Maybe they'll buy the crappy non-adjustable ball joints (that they provided) from me.  Maybe not...

08/25/2000 - Fender work
I began my fender work tonight.  Since I had to move the front axle back one inch, I had fender clearance problems when the front tires are turned and the suspension is compressed.  I had already cut as much of the lip off as I could so I had to make more drastic changes.  I used a chisel to cut the spot welds holding the fender together.  Then I pushed the back section of the fender back about 1 1./2".  I used one of the bolts that hold my Off-Your-Rockers on to mount the inner fender section at this new location.  Tonight I nearly finished the drivers side fender.

08/26/2000 - More fender work
This morning I finished the drivers side fender and then began work on the passenger side fender.  I was able to complete it by the early afternoon.  Around 7pm Natalie and I decided to take the Jeep for a test drive in Big Bear.  We loaded up the camping gear in the Jeep and loaded the Jeep on the trailer.  I wanted to test tow up Big Bear mountain anyway.  The Tahoe towed great.

On the way to the camp site in the Jeep, the head lights began flashing.  I still do not know for sure why this happened, but I'm guessing it's a loose connector behind the dash.  I checked all the fuses to make sure they are properly inserted, they were OK.  Since both head lights are flashing together I'm assuming that the problem is not under the hood.

08/27/2000 - Test drive
I drove through 3N93 at Big Bear today.  All went very well.  I only discovered two problems and they are not related to the new front axle.  One, the nuts holding my traction arms to the rear axle came loose.  I'll have to change these for fine thread nuts and bolts.  The second problem was a fuel leak from the fuel filter.

08/28/2000 - Minor fixes
Tonight I got new 5/8" nuts and bolts to hold my traction arms to the axle.  I also installed lock washers.  I don't think this will be a problem again.  Next I installed a new fuel filter and replaced the rubber hoses at both ends of the filter.  I found a tiny hole in the filter because it was not properly secured in the mount.  I guess it's been rattling against the mount which cause the tiny hole.  Next I removed the rear brake rotors and cleaned the rust and white paint from them.  I also cleaned up the ends of the rear axles.  After that I applied a new coat of black paint to the ends of the axles and to the area of the brake rotors where the wheel mounts.  No, I didn't paint (or over spray) the part where the brake pads touch, DUH!

10/16/2001 - Tri-County messed up
After putting about 1,000 mile son my Jeep over the last year, the right rear axle end oil seal began leaking.  Tonight I took it apart and discovered that when Tri-County re-geared the axle, they didn't install the axle shaft retaining plate correctly.  They forced it together which bent the plate and eventually caused the oil leak.  Now I have to have the bearing removed (press fit) and replace the seal, spacer and retaining plate.  Thanks for your continued customer service and quality of work Tri-County Gear!

10/18/2001 - Cost of Tri-County mess up
The bearing and seal cost $45.  Another $25 to have the new parts pressed on the axle.   All because they didn't pay attention when they assembled the axle.