The patience requirement alone will keep guys like me from being guys like you. And let’s not even consider the organizational needs. Yikes. I like piles. Loosely themed piles.
Final result, running in the pattern.
That’s before we mic’d and organized all the shims into piles
Excellent work! Cool video. What kinda oil you gonna put in?
Nice contact patch.
I admit, I had a lot of help with this one. Almost every spec from a regular D44 to the New Generation D44 has changed. I was very unprepared this time around compared to before when I had all the tools and time to do the job. If it weren’t for Mike this wouldn’t have happened. He knows these axles inside and out. I was basically a helper and student today, and learned some additional tips and tricks working on gears today.
Dana wanted to rename the axle, Jeep protested and won that battle.
Rebuilt the axle shafts too since the bearings were contaminated with the liquid metal gear oil…
Do it right the first time and you will not have to do a second time.
Job well done.
How did you get backlash set? Spacers/shims? Trial & error?
Once pinion depth is set, which is THE most critical setting, backlash is set with shims on the carrier moving the ring gear closer decreasing backlash, or further away from the pinion increasing backlash.
Reusing the shims previously installed the left was .120, the right was .135.
For my set up that gave us a backlash of .004, too tight.
We’re looking for .006 to .010.
Taking .005 out of the right side for a net of .130, and adding nothing additional to the left side resulted in a backlash of .008.
Perfect, right in the middle of the specs. 
It’s about distance of pinion gear in relation ring, correct?
Pinion depth establishes the pattern for the most part, carrier shims affect backlash for the most part
But everything affects everything if that makes sense
So no forward/backward adjustment?
I asked after you explained, sorry.
Pinion depth is the forward/back if I understand correctly.
Carrier bearings seat into the housing and are fixed. They can not move in or out.
10-4
Your accomplishment has given me a sense of confidence that this is something I could take on now. I have changed axles and pressed bearings on and off, etc. Replaced pinion shaft seal and retorqued, but haven’t rebuilt yoke.