jk dana 44 front build - pinion assembly questions

I am finally getting around to putting the guts in my bare JK d44

I have found different exploded diagrams that show contradicitng things about the order of parts that go on the pinion.

We'll use this one for illustrating my questions.

Parts in order, inside to out

Pinion
-Slinger/No slinger ? (some diagrams show it, this one does not?)
-Inner Bearing/Race
-Baffle (68004076AA)


//Diff Housing//

-Assortment of shims to set pinion preload
-Crush sleeve
-Outer race/bearing
-pinion slinger (68004073AA)

-seal
-flange
-etc....

Missing anything? Sucks not having one to take notes on as I pull it apart...

WTF, you read one writup and it makes sense then , look at the parts diagram and nothing matches.

Okay, screw that diagram....

Pinion
Shims(to set pinion depth)
bearing/race
Baffle (68004076AA)
//Housing//
crush sleeve
bearing/race
pinion slinger (68004073AA)

Now I just need to figure out initial pinion shim stack thickness for D44

I admire you for taking to plung doing it yourself. For me, it would have been too costly a learning experience if I'd done mine myself. I let Robert at ORR have at it (he did some great welding on my D44 too).

A differential is about the only thing left that I haven't done...most of the ones I had built in the past were for a ford 8.8 in my track car and I had a guy that did them for $150. That was a bo brainer.

But when youa start talkinga bout $400 for each end...I'll take time to do it myself.

I understand the overall process of setting up the diff, it's just the nuances in components from one diff to the next...even among the different D44 variations. You look at three different diagrams and they are all different.

Some set pinion depth with shims behind the race, some between pinion head and bearing, etc...

Then the preload, shims vs crush sleeve. I was trying to hone out an inner pinion bearing to use for setup bearing, need more aggressive stones for my hone.

Here are some pics of axle reinforcements:

Nice!

nice work. Makes me wish I had the $$ to get me a welder.

You are welcome to use mine anytime...just let me know. I need to upgrade to a larger tank...seems like everytime I am in the middle of a project a end up running out of Argon/Co2.

I got a great deal on my Hobart 140 from a friend. He was upgrading to a 185. I learned on a Millermatic 210 and I need to find something equivalent to that eventually. I miss having the capacity it provides.

I also want a TIG, but many other things higher on the priority list for the near future.

Ended up having Robert over at Off Road Ready put them in...he did a great job. That'll leave me some time to catch up on other projects...like finishing the cage in my race car.

I need to hook up the ARB and compressor this weekend...

Well, after 8 months of these things sitting in the garage....the RCV shafts are finally in. Will be running air lines and switches for ARB tomorrow.

Compressor wired and locker sure as hell works...ready to go play

congrats!!! now get some wheeling pics