Possible D44 HD/AL swap... vss?

u2slow · **Joined:** Sun Mar 11, 2012 7:26 pm **Posts:** 160

I picked up an aluminum D44 (3.73 open) from an '04 WJ. Bargains get the best of me :lol:

I notice this thing has two (ABS) speed sensors, one at each brake backing plate. My KJ only has a single sensor on the diff pumpkin; and no ABS whatsoever.

Does anyone know if the ABS sensors produce the same signal as the diff speed sensor?

Mountainman · **Posted:** Wed Jul 15, 2015 10:53 am

u2slow wrote:

I picked up an aluminum D44 (3.73 open) from an '04 WJ. Bargains get the best of me :lol:

I notice this thing has two (ABS) speed sensors, one at each brake backing plate. My KJ only has a single sensor on the diff pumpkin; and no ABS whatsoever.

Does anyone know if the ABS sensors produce the same signal as the diff speed sensor?

hmm, they are both proximity sensors I believe, but the one on the backing plate counts teeth, so I don't think there's a prayer in it working, despite gear ratios near where the sensors are mounted. However, you might be able to tap the dif in a suitable location and if you can get the sensor the correct distance from the carrier, or whatever they sense, then it should work, unless the dif mounted sensors also have a ring of teeth that they count (pretty sure they don't).

Proximity sensors are designed for a specific distance range from the metal that they are sensing, so if these particular sensors have a really small range, then it will be really tough to fit them elsewhere.

Then again, I'm sure one of the dif experts will chime in and let you know if you have a chance. Or, are the dif sensors gear driven? I don't think so.

tommudd · **Posted:** Wed Jul 15, 2015 11:10 am

First question is why you'd want to install that diff in the first place
Most want to get rid of them

u2slow · **Joined:** Sun Mar 11, 2012 7:26 pm **Posts:** 160

Like I said, bargains get the better of me. :mrgreen:

Well aware of the pro's an cons of the 44a.

If the VSS at the backing plate will work, I have the option of splicing in a D60 center I have kicking around along with 4.10s and a Lockright.

JeepMorrison · **Joined:** Thu Jul 16, 2009 11:34 am **Posts:** 1236

D60 with 32s?? Hahah your gonna be dragging that thing over everything

WhitbyKJ · **Posted:** Wed Jul 15, 2015 3:59 pm

Luckily I have had both, so I can chime in here.

The dana 44a you got from the wj won't directly bolt in per say, some bracketry needs to be moved around at the lcas I believe. The boomerang from the wj will bolt in. Not sure if it will set the pinion at the right angle or not tho. There was a guy around on a forum somewhere who was making a truss for the 44hd that bolted to the diff and welded to the tubes to stop the tube from spinning/bending. Almost bought one myself.

Now the kj 8.25. What a beast. I don't know why you'd wanna swap it out? But then again I do crazy stuff I probably shouldn't just for the science, so I cant judge. Seriously tho..

The kj ring gear, has a 1/16th thick tone wheel that sits underneath the ring on the carrier. On this tone wheel are teeny tiny teeth.. Almost like what you'd find on a saw blade (wood hand saw, maybe even more tpi than that). If you were to count the teeth, and have a gear/spacer with the same number of teeth made for your d44a.. It is possible that you could reuse your kj sensor.

Not sure if it would work, but I would scan an image of the kj gear, then scan an image of the d44a ring gear, and see if it possible to Redrill the kj gear to fit the d44 carrier? If it is possible the two can mate, you will need to remove material from the backside of your ring gear (dana44) to make up for the added kj gear. Remember this may or may not work lol.. But with enough patience anything is possible.

See what I'm saying? As long as the sensor see the same number of teeth per revolution as it normally does, you should be good.. Unless it's possible to just reprogram the thing, I dunno.

WhitbyKJ · **Posted:** Wed Jul 15, 2015 4:09 pm

Or a simpler idea, see if it's possible to have a gear shop, cut the same pattern right into the d44 ring gear.

u2slow · **Joined:** Sun Mar 11, 2012 7:26 pm **Posts:** 160

I see there's GPS and other calibration modules that can be had to feed the speedo a useful signal. I just wondered if anyone has successfully used one of these ABS wheel speed sensors directly in place of a diff mounted tone ring sensor.

WhitbyKJ wrote:

But then again I do crazy stuff I probably shouldn't just for the science, so I cant judge.

That about sums it up for me too :seuss:

I think it boils down to my reluctance to dump $$$ on gears and traction for the 8.25" when I've got beefier options kicking around (D44a, 9.25", Ford 9"). It just happens my smallest 4.10 gears are D60, and my spare Lockright is D60 30 spline. I've pretty much decided any further mods to the KJ have to contribute to the eventual SFA swap. The gf gets pretty excited when she sees Jeeps on 35's.... even 33's :JEEPIN:

WhitbyKJ · **Posted:** Wed Jul 15, 2015 6:52 pm

Ya, I'm feeling 33's coming soon.

mass-hole · **Posted:** Wed Jul 15, 2015 7:15 pm

u2slow wrote:

I see there's GPS and other calibration modules that can be had to feed the speedo a useful signal. I just wondered if anyone has successfully used one of these ABS wheel speed sensors directly in place of a diff mounted tone ring sensor.

WhitbyKJ wrote:

But then again I do crazy stuff I probably shouldn't just for the science, so I cant judge.

That about sums it up for me too :seuss:

I think it boils down to my reluctance to dump $$$ on gears and traction for the 8.25" when I've got beefier options kicking around (D44a, 9.25", Ford 9"). It just happens my smallest 4.10 gears are D60, and my spare Lockright is D60 30 spline. I've pretty much decided any further mods to the KJ have to contribute to the eventual SFA swap. The gf gets pretty excited when she sees Jeeps on 35's.... even 33's :JEEPIN:

I wish my wife got excited about 33's

Arkie · **Posted:** Wed Jul 15, 2015 7:18 pm

mass-hole wrote:

I wish my wife got excited about 33's

Millimeters? :goink:

Bob

mass-hole · **Posted:** Wed Jul 15, 2015 7:20 pm

From the top rope.

tommudd · **Posted:** Wed Jul 15, 2015 9:31 pm

u2slow wrote:

I see there's GPS and other calibration modules that can be had to feed the speedo a useful signal. I just wondered if anyone has successfully used one of these ABS wheel speed sensors directly in place of a diff mounted tone ring sensor.

WhitbyKJ wrote:

But then again I do crazy stuff I probably shouldn't just for the science, so I cant judge.

That about sums it up for me too :seuss:

I think it boils down to my reluctance to dump $$$ on gears and traction for the 8.25" when I've got beefier options kicking around (D44a, 9.25", Ford 9"). It just happens my smallest 4.10 gears are D60, and my spare Lockright is D60 30 spline. I've pretty much decided any further mods to the KJ have to contribute to the eventual SFA swap. The gf gets pretty excited when she sees Jeeps on 35's.... even 33's :JEEPIN:

Wouldn't call a 44a beefier than a 8.25
out of all listed that would be my last choice , well really wouldn't even be one of the choices

tjkj2002 · **Posted:** Thu Jul 16, 2015 1:12 am

tommudd wrote:

u2slow wrote:

I see there's GPS and other calibration modules that can be had to feed the speedo a useful signal. I just wondered if anyone has successfully used one of these ABS wheel speed sensors directly in place of a diff mounted tone ring sensor.

WhitbyKJ wrote:

But then again I do crazy stuff I probably shouldn't just for the science, so I cant judge.

That about sums it up for me too :seuss:

I think it boils down to my reluctance to dump $$$ on gears and traction for the 8.25" when I've got beefier options kicking around (D44a, 9.25", Ford 9"). It just happens my smallest 4.10 gears are D60, and my spare Lockright is D60 30 spline. I've pretty much decided any further mods to the KJ have to contribute to the eventual SFA swap. The gf gets pretty excited when she sees Jeeps on 35's.... even 33's :JEEPIN:

Wouldn't call a 44a beefier than a 8.25
out of all listed that would be my last choice , well really wouldn't even be one of the choices

Yep the D44a is a bad choice and only lunch box lockers to boot.The KJ's 8.25 is a lot stronger then the D44a and you have much more(and far better) choices for lockers.

If your even thinking about a SFA swap in the future save your $$$ for that.Plus you don't even want a D60 for 35" tires(unless you opt for a dynatrac or RockJock60) let alone a D44a.

WhitbyKJ · **Posted:** Thu Jul 16, 2015 7:49 am

My old man runs 35's on his dakota (8.25) all day long.. Never had a problem.

Mind you, he doesn't gun it.

u2slow · **Joined:** Sun Mar 11, 2012 7:26 pm **Posts:** 160

Points taken.... I'll continue to ponder my options. :juggle:

This thread gave me some fuel for beefing up the 44a
http://www.pirate4x4.com/forum/axles-ti ... d-box.html

mass-hole wrote:

From the top rope.

Arkie wrote:

mass-hole wrote:

Millimeters? :goink:

Bob

Possible D44 HD/AL swap... vss?

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