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Thread: 44-9 Hybrid axle build

  1. #1
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    44-9 Hybrid axle build

    So I picked up a pair of ford 9" axles to upgrade my XJ.

    specs are detroit locker front with 5.13 gears and spool rear with matching 5.13 gears.

    Once I got the axles home I proceeded to inspect the construction of the front (44-9) with scout outers. It was not up to my standards, so a cutting I go. I need to attach the c's straighter then they were and rotate them to get the correct amount of caster as I drive my rig to and from the trails.

    The plan is to sleeve the exsisting 9" tubes with 2.75 od dom so that the 'c' can be put back onto the end. I will put this tube completly through to the other side of the axle in one piece so that the c's are square. Then I will cut out the tube where the 3rd member goes in. This also gives me a good location to put the facorty d44 axle seals.

    I will post a few pics later...

    If anyone has any tips please feel free to speak up.
    1986 2 door XJ, 2.5L 5 spd, 231/300 twin sticked,
    8" lift, 36" IROKs, 44-9 frt axle with 5.13's and a detriot, rear 9" with 5.13's and a spool, custom track bar, custom snorkel,
    9500lbs winch with custom front and rear bumpers, SBS, Staang's FAB front and rear longarms, crossover steering.
    http://www.youtube.com/staang
    Need any Mechanical or FAB work done PM me or visit my website

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    I dont have any tips or tricks, but will follow closely as this is what I am looking to do with mine sometime in the next year or so.

    The axles you picked up already set up for a front and rear, or was it two rears? Any idea what your doing with 3rd members? LP's or buying an aftermarket HP?
    Pete
    -'04 TJ-

  3. #3
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    The front was already setup... just not to my liking.. I'm gunna run LP to start then upgrade as I go... That is what I like about this setup.. easy upgrades.. d60 outers, HP, lots of gear choices ect.

    Would love to put in a tru hi 9 but to much $$$ currie has a nice setup I will pickup in the fall/winter for the front.

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    I have to agree thats why I am looking at it the options are endless really. And the all steel housing is icing on the cake, to weld brackets, trusses, or whatever...

    I had priced out the Currie, it was more for the Hi9, but I didnt think that much more. The Currie HP doesnt have the Daytona support, where as the HI9 maintained that extra pinion support, if I could swing it thats the route I would take. But I will be doing mine real slow over the next year or so, just gather and collect as I can find it cheap. Figure the 3rd members and front shafts are my big tickets.

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    3rd member and axles are the only big ticket items... and even shafts aren't that bad. I have corprate 10bolt inner axles. The short one fits perfect and the long one needs a lil shortening.. that is the inexpensive way of doing it.

    I'm only running a 4cyl so the currie HP will work just fine.

  6. #6
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    This is how the axle sits now. c's cut off, just waiting for my DOM tubing.. picking it up tomorrow.





  7. #7
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    Sounds like an interesting setup. Watching closely! I would suggest upgrading the scout outers. The Locking design is week and might as well go to high steer while your at it (wish I did).
    90 YJ. 4link F/R, 16" SAW Airshocks, 32bolt Beadlocks, D60/14bolt, Full Hydro/Hydroboost L67 3.8SC 700r4 NP231/D300
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    I prefer to build it and not buy it, you see it, I probably made it.

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    I have drive flanges for backup if the hubs blow. I'm not turning them with alot of horse power either. If they are breaking I will upgrade them. Thanks for the heads up.

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    Good Idea. Same reason why I kept my drive flanges instead of tossing them. What hubs are you using. Also I've seen your flex. Not worried about the LP Front for now? I haven't even run mine and I'm lining up a HP replacement.

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    Got me a pair of warn premiums for hubs. And if the drive shaft binds I'll just strap it for now. HP's coming in the fall forsure hopefully sooner!

  11. #11
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    Same lines as me. I have to strap mine as it stands now. Look to go HP soon. I would love to see you setup in person. Just never in the area.

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    BTW Need an High Angle Tom Woods U-Joint, got an extra.

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    PM sent!

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    I now have the axle housing sleaved.

    Still have to trim the ends, truss it and add gussets to the inside before the center of the tube is cut out.


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    With all that work done to a used, thin housing wouldn't it be easier and way stronger to just start with a spider 9" housing or a Diamond 9? I know fab is half the fun but there is way better stuff out there for well under a grand.


    this is only $499
    Last edited by Chrisbuilt; 03-13-2009 at 10:49 AM.
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  16. #16
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    So true, but I have VERY little invested in this, so it will work for now. I can always upgrade down the road. It's all just labour time anyhow, thats free to me!!

    That housing is real cool, but for $499 US, I'd rather buy a HP 3rd for the same price.

    My housing should be way stronger when I'm finished too. The axle housing has 1/4 wall seamed tubing and I just sleaved it with 1/4 wall DOM. Should be able to jump this sucker when the truss is on.

  17. #17
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    Excuse my ignorance but is that a 9" centre section with 44 tubes pressed in? or am I retarded, and how does the rotation of the gears work?

    Thanx
    GO HARD OR GO HOME !!!!!!!!

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    Yes, a 9 inch housing with tubes to fit d44 inner c's pressed into the exsisting 9 inch tubes. The gears will just drive on the coast side of the gear. Not the best way, but will be WAY stronger then the d30 I have in there now. I will be upgrading to a HP 3rd and reverse rotation gears come this fall, which will have the gears driving on the proper side.

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    Thanx for the explination, I was thinking about doing the same myself to match my rear 60

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    [QUOTE=Staang;892085] I have corprate 10bolt inner axles. The short one fits perfect and the long one needs a lil shortening.. that is the inexpensive way of doing it.[QUOTE]

    So the 10bolt inner shafts have the same spline count, and diameter as a normal 9" 31spline shafts? I tried to find if this is true elsewhere but nothing I could find could confirm exact dimensions on the shaft O.D. and spline count.


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