CORRECTION: Thanks everyone for the comments. My math was off. The Dana manual says: If the old pinion reads ( + ) 2 and the new pinion is (-) 2, add .004" shims to the original shim pack. So a negative number gets subtracted from the nominal bringing it closer to the pinion and a + number brings it farther away...

For those of us who learn by watching not reading, tips and tricks are priceless. Keep up the good work Paul always a pleasure watching your videos.

Paul, thanks for this video. I would encourage you to do more of these differential videos if you want to branch away a bit from transmissions. Your way of explaining things would be a big improvement from all the other videos that I have watched. We all appreciate your attention to detail and the extra little tips that we receive from you so please go for it. We will enjoy and learn I am sure.

EXCELLENT. Loved the time taken to touch on shop safety. Nobody gets a "hardass" award for losing an eye, getting their throat cut from a cutting wheel, or losing fingers. Excellent video altogether. Top notch.

Okay, I think I'm a pro now.. Headed to the driveway, wish me luck!

That really was well done. I like how you used an old transmission case to hold the pinion while pressing out the bearings. Also how you supported the pinion when reinstalling. All good tips. I have to go through my Dana 44 on my Studebaker and this helps a lot. Thanks.

Brilliant summary! I've been waiting to find this video for over 5 years.

One of the best videos I've seen on d44 gears. Great job.

I’m getting ready to do a 44 and have probably watched 100 videos, this one explained the “why” better than any. Thank you!!

This is the best video I have found explaining the entire process. Thank You.

That is "The" best done video on how to work on a vehicle I've seen. You really know your stuff. Fantastic.

I'm in the middle of freshening up a badly rusted Dana 60 Front, GM King Pin. Your video was a great help, Thank You! Now I've rebuilt 12-bolts, 10 bolts, 14 bolts, but this Dana 60 Front has been a labor intensive endeavor simply because of the crude engineering of the shim placement. I use an OTC bearing splitter exactly like yours and have even sharpened the leading edges to minimize damage to the shims as well as the carrier and the pinion. It still wiped out the shims and rolled a bit of a shoulder on the carrier, nothing a file couldn't take care of. One surprise was the "lock bolt/pin" that locks the spider gear pinion shaft in place inside the carrier. I had thought the previous mechanic had broken the bolt and reassembled the unit. Wrong, this Dana 60 uses a 3/16" x 2" roll pin! I didn't realize this until all my extractor efforts failed and I resorted to punching out the spider gear pinion cross shaft shearing the roll pin. I then realized that Dana has a hole completely through the carrier to drive that roll pin out. Tough lesson, a six pound hammer and a 3/4" bull pin drove that cross shaft right through that roll pin and right on out on the 3rd blow, no damage. Oddly enough there was exactly .100" thou. of shims split 65/35. I actually used a small bottle jack under the pinion sitting on a 4x4" tube steel leg off my engine puller. I used grab chains suspended from each end of the axle supporting the steel tube. That allowed me to use the small hydraulic jack to push up the center of the housing while the chains held down the axle tubes and I was able to open the case .005" of an inch one thou at a time. The dial indicator let me know how far and also let me know when everything sprung right back to zero. To bad those Corporate 14-bolts don't come as front axles because they're way easier and stronger than the Dana 60's...I think I may look into a reverse rotation gear set for a 14 bolt and use Dana 60 King Pin castings and yokes...? Thanks again for this and all your videos, I like your no BS way of explaining things! ;)

Great video mate. It’s not a full course on diff building but for a novice it was SO easy to understand and made things self evident.

Just finished watching the video. I just marvel at the decades of experience, knowledge so hard come by, communicated in such a simple method in only 46 minutes. Can you boys imagine how hard this simple job for Paul would be for us fellas if this video wasn't here. And Paul's giving away these decades of experiential knowledge FOR FREE! Absolutely mind bottling!

Differentials have been "the last frontier" on cars for me. I've removed axles to change outer bearings and seals, but nothing else. ETCG just made a video about putting a kit in his father's truck diff, but I didn't quite get it. Your video helped me understand a lot. Also, as a DIY/hobbyist, it's refreshing to see a real master using "regular tools". I priced your bearing cone heater from another video and gave up the fantasy of owning one - so happy to see you using a heat gun (already have one). Thanks for sharing your knowledge here.

I'm digging the clamshell puller! Learn something new every day.

Thanks for the tip on using a heat gun for the bearing. I used my cheap Harbor Freight heat gun and it put out 300 degrees of heat on the bearing. Once the bearing got to 150+ I dropped it right onto the pinion, no fuss, no muss. You saved me a lot of drama.

Great video, I am currently debating changing my own gears in my Dana 44's ( I work as a Millwright currently ) and after watching your video I know I will have the confidence to do this.

I'm getting ready to rebuild my D44 front on my ram, the pinion is so loose I can shake it around with the driveshaft. Most of the other videos on KZfaq either skip things or just leave out parts. I learned a lot from this, especially about preload. I plan on installing a lunchbox locker for off roading and have a cable actuator to replace the vacuum disco. Thanks for posting this

Genius way to verify/check pinion depth and you are right, much cheaper than buying the tool. You just saved me more than a couple hundred bucks. Thank you!

Great advice on safety precautions when using chisels, especially air hammers. I’ve had “shrapnel” from just a cold chisel and hammer go into my hand when removing bearings off axels.

Great timing for me to see this video. I'm getting ready to change the pinion bearings in my landlord's jeep commando and swop out the front ring and pinion in Jeep. Now I have all the information I need to get both jobs done. Thanks for your excellent tutorials. I watched your tutorial on rebuilding my Muncie 4 speed. It really gave me the confidence to get it done right. Been running it for almost a year now and it works great!! Thanks again.

Even though I'm not going to do a dana 44, the science was really good and applicable for other setups. Thanks for taking your time to put on these schools, good stuff.

So after several trial and error installations, I finally got it set right, THANKS TO YOU! The tight spot I mentioned came from the yoke against the new seal. There is a sheet metal collar around the pinion side of the yoke that was corroded and deformed. I removed this collar and my tight spot went away. The new seal was different than the old one. Not sure why...new and improved? Ugh...but I'm on the downhill run now!

Very good! Great explanation! I want to regear my Cherokee and this was a good review at the end of your video. I did what you did on an Chevy Astro van I had just bought with a noisy rear end. The vent tube fitting came off and the housing filled with gravel. Fortunately the gear set was okay but the bearings were hamburger. Kept the shims the same and it worked out great. I fixed the vent tube...

Nice money shots at 7:25 ;) You do really well with the AV equipment you have... In addition to being wonderfully educational. Lots of headache-saving tips for the DIYer, thanks!

How technical, you were able to hold my attention from start to finish. That's good stuff and just the way I I like it, you are obviously a master at your chosen profession, my hat is off to you sir, keep up the good work and the videos. Thank you so much.

Great introduction to the internals of the Dana 44. Looking forward to further videos on this differential.

I learned a lot from your video..... including how to use race and bearing drivers, installing and removing bearings using pullers and heat guns, and setting pinion preload. I really enjoyed watching, and liked your very informative instructions and tips. Thanks !

Really helpful! Now i´m gonna go out and dissassemble the diff on my Volvo C202 (Dana 44´s from Salisbury) and do a pinon bearing swap. Thanks for sharing your knowlege!

I want to thank you for taking the time to make this video, great information!

Thanks for this. Just picked up a 44 and now I know how to refresh it.

great video. I like the way you dispel the old myths and wives tales of assembly.

Hi, Your experience is priceless, your videos are classic. Why I’m saying your videos are classic? Because today’s day we don’t do that type of repairs specifically in car dealers. It always pleasure to watch your videos because whoever watching your videos they learn something including me. Thank you for sharing your hard lifetime experience to the world.

I sure enjoyed the lesson and I am eager to get my front differential done it's a dana 44 closed knuckle on a '68 ford f250 4x4 highboy thank you again for your help

Now that I'm into this and I get it now , it's just a starting point. man I've had like 3 people tell me to just torque the pinion nut down to the specify torque reading and I'm good,,,,, well their nuts and I'm glad I watched your video! like 5 times! Thanks

If I have to replace my pinion bearing, i feel confident in doing so after watching your video! Simply amazing! You're very good at what you do! Thank you very much!

Watching this video just helped me decide. I'm having a professional rebuild the rear end in my Jeep. Thanks for the great video.

Video was extremely timely given issues I am having with Dana 44 rebuild. You have taken a complex process and broken it down so the average person can readily understand the procederual steps involved in pinion bearing preload drag and carrier bearing 'math' to assist in setup. Thank you for the great video and assist; your presentation skills are excellent.

That trick with the bolt and the wrench with the pinion nut is sheer genius!

Always fun to watch someone do this, when I don't have to.

I've got two leaking Dana 44 pinion seals on my Rubicon. it's been a long time since I worked on a differential assembly. thanks for the video!

Great! The Dana 44HD rear diff. on my 73 International 1210 needs repair; what luck! Thanks Paul!

Great video Paul. Thoroughly enjoyed that. Taking the mystery out of the black art of differentials.

this was an excellent video..i like the way you work and talk .......you have a good way of teaching,,,,,,,and a good attitude and no cursing,,,,,,,,,,,great job........thankyou

i like videos of people that know their stuff,your good,i worked at a GM dealership for many years,i was taught by a man similar to you ,in other words he knew his stuff

One of the better videos on setting up a differential, very well presented, THX

Enjoyed your video.Did same job on a Jag many years ago.Like the way you work

Great video, Probably the best I’ve seen on the Dana 44. Subscribed!

Great video. It also shows how important having a bit of knowledge about the underlying mechanisms which you’re using to be able to actually do this job DIY. Your experience is obvious. But I appreciate your attention to detail and your explanation. I’m listening to a slight whine in my Dana44 now and I will be referring to this video when it’s time to rebuild. Thanks

Very well described . This is what I do for a living. I have replaced may pion seals and never replaced crush sleeve and so on. Other parts of you video great job.

Very informative from a guy with a very loud rear end '96 Grand Cherokee.

Sweet trick using ground bar stock and a depth mic to check pinion depth. We used housing spreaders back in the day when working on Dana 70’s & sometimes 60’s. It doesn’t take much to “spread” the housing enough to pull the diff out. BUT, those things can be dangerous when using on an axle in chassis!!! They can and WILL fall out of the dowel pin holes on the housing and could break an arm or two. Very heavy tool. We would chain them up in such a way that if they slipped out of the dowel holes, the chains would keep it close to in place. Great and thorough video! Thanks for posting👍🏻👍🏻

Hello Paul, just want to thank you for the amount of time and effort spent filming and editing these excellent videos. It is truly appreciated by myself and all your faithful subscribers. Thank You.

Well I think I got about 1/1000ths of this. Only because I am totally clueless but I can’t help but look at your amazing knowledge and the complexity of these devices. Thank you for sharing.

The best video I ever watched. I've learn so much, and it was so interesting that I didn't realize the video was 45 minutes long. It seemed to be a lot less. Thank you so much for sharing your knowledge. For sure I subscribe immediately.

Hey Paul. I am so glad you did a video on the Dana 44 (another Super Job by the way). I have rebuilt a GM 8.5 with a new center section and was looking forward to doing a Dana 44. I read a lot about rebuilding the Dana 44 and am glad to hear the spreader is not required, though everything I read stated to use the spreader for the Dana differentials. Keep up the good work; everything you do is of great interest to me. Marc

Thanks for this fine work. The explanation with the details is very cool and it is practical and scientific at the same time. We appreciate your effort in making this video. You contribute to publishing your experience to all people for free. God bless you

Thank you Professor for the Dana 44 class, wow not doing your self project for sure, what ever you charge for the repair well justified 👍

Thank you very, very much! This video must be placed on the top YT videos! Greetings from Brazil!

Wonderful video. Thank you for telling me interesting things and showing me the repair methods. Hello from Russia

Paul, Great instructions and presentation. I was lucky to have a friend who was service manager at Ford to borrower the spreader for the Dana 60 to put 4:56's in my Street Hemi, otherwise, I would have been S.O.L.. Gee, a little over 60yr. ago. already. BTW, use to go out to NY National Speedway, in your neck of the woods, or was that potato farms.😃

This video is definitely a confidence builder,it's very helpful.I have been wanting to do my own rears and with this I am a little closer.You said you sell that tool you were showing for the bearings I would be interested in that tool...Thanks again for a great video.

Thank you for making this video ...it all sounds so simple yet is so complicated...I learned an awfully lot..I'll leave an apple on the desk teach.

Man, i really like your stuff! im doing this very same thing at work right now. only it's not a rear it's a press gearbox with bevel gears and cams and flange bushings etc. Thanks for the lesson! L.C.

Thanks! That's a great tutorial, definitely will help me in rebuilding my series 3 Jag XJ6 center section.

Great video, you explained the pre-loading with the crush sleeve very well. thanks

Appreciate the video my man.... What you did is exactly what I'm about to do... I bought a GM Dana 44 front that needs complete rebuilding of all seals bearings all the way out to the hub the carrier and gear set seem to be in good shape... Thanks for the insight

Really nice video !! Great to have such a clear and concise explanation for all the "why's" !! I'm a fan.

Awesome video, I'm in the process of rebuilding my Dodge Viper differential, and this was super helpful

Bro i love how you explain and make your videos educational.. Solid gold keep explaining like you do.. Two thumbs way up

Very cool how you took the video off in your hands!

What a pleasure it is to watch a man who very obviously knows what he's talking about !!

Good video with some great tips especially around pinion depth shimming and heating the bearings. I found this at the perfect time as I am refurbing my Jaguar E type diff!. You might want to update the title with XKE or E Type. Thanks again from Oz

Thank you very informative You filled in a lot of blanks for me as far as shims go now I have a better understanding. Thank you for your help.

Excellent education. You're a good teacher and a new valued resource.

Great to watch a pro work..

Good video, like that clam shell puller, like a big power steering pump pulley puller. I carefully used a cutoff tool and chisel. Very educational.

Very informing and helpful. I am replacing carrier and pinion bearing on my dana 27. I really should have purchased a second set of carrier bearings to hone out to may life easier on set up. Even though the cups & bearings were matching Timken #'s, it's a bear to re-pull if required. I too don't like using a spreader.One can spring are damage a case in blink of an eye. Thx, Bear

Really good Mate.. Working on a Dana 80 at moment. Guessing much the same other than no collapsible spacer. Good to know i don't need to adjust shims as I am only replacing bearings :)

That Clam Shell Bearing remover shows that necessity is the mother of invention. First time seeing it. Looks like it works good.

Having done gear repair myself, i can tell you know what your talking about, thats a really good video!

GREAT VIDEO. I HAVE A TRUCK PROJECT THAT I'M MAKING PROGRESS ON, I HAVE THE MOTOR DONE EXCEPT FOR THE ACCESSORIES. I HAVE A SM465 THAT I JUST GOT THE COUNTER AND MAIN SHAFT INTO, SOME TORQUING AND PTO COVERS AND IT WILL BE DONE. I WAS GOING TO REBUILD THE 2O5 TRANFER CASE, BUT FOUND A GUY THATS BEEN IN THE. MANUAL TRANSMISSION REBUILD FOR 36 YEARS AND HE IS SELLING OFF HIS STOCK, SO GETTING A GREAT DEAL ON A 205. THEN ITS TIME TO MOVE ON THE DIFFS , MINE ARE NOT DANA 44, THINK THEIR ARE C 10 ,I DID CHECK THE BOLT PATTERN BUT FORGOT. YEP ITS COMING TOGETHER. WANT TO THANK YOU FOR ALL YOUR ADVICE AND HELP AND THE VIDEOS.

Love your videos. Your videos bring back some memories that are so strong that you can almost smell gear oil right through the screen. :-)

Learn more in less time from watching your video than anyone would watching all the others put together. You're like the godfather gearboxes and diffs ;)

So I'm about to replace pinion and carrier bearings on my Jeep Grand Cherokee. Dana 44A(aluminum alloy housing) I brought it home, new to me, and it had a whine. Removed the cover and the gear oil was mettalic. No metal chunks. I sprayed it out with brake cleaner. So the carrier caps are not on correct, as you have described, as well as other video's described. So the line bore was all out of whack...I bought a new bearing kit and will be changing them soon. I hope my carrier caps will be ok, and not distorted enough to be beyond use.

Thanks. I am thinking about buying a ’85 CJ7 and the owner says it has a bad pinion bearing. Now I know what I would be getting into if I should decide to try the repair on my own. Great video.

Great video, good information, good recording, basic tools, couldn't ask for more...

Well explained, great video angles and video quality. Only watched two videos so far, very promising: good advice for an amateur like myself that doesn't have the complete professional setup, but have sufficient experience banging my thumbs with a mallet. Subscribed of course.

I love to watch experts 👍

This is the best explanation of differential bearing replacement I have seen to date. I'm faced with not only bearing replacement but the ring and pinion as well. It might sound extreme but since all the spacing (shimming) will probably change, which will require assembly and disassembly a couple of times to get my shimming correct,, would it be best to buy an extra rear pinion bearing and the carrier bearings (outer races) and lightly hone them for making them easy to install and remove. After I have my shimming established I could then install fresh tight bearing races for final assembly. Any thought you have about this would really be appreciated. Knowing what goes into this job makes it extremely scary when it comes to letting a local mechanic's shop do it, not to mention the cost.

This is such an awesome video. I really like how thorough you are.

I want to ditto Joe Clark. You do an excellent job of explaining. I would love to add a posi to my chevy van. Now looking at your video, I feel like I can. I will be looking more of your videos. Thank you

Another good video. I have read about all the stuff you need to do to get the right alignment but really it is not a home garage job unless you do it for a living. I think I would just pay to get it done like your customer and avoid the headaches and the despair of not getting it right and having a noisy diff.

Good vid!! I am about to do a D44 swap on my Mitsubishi Mighty Max, The donor axle will come from the rear of a 4x4 93 - 97 Isuzu Rodeo. I will have to cut the axle down and have the shafts rekeyed as the axle is 2 inches wider than my factory axle.. Thanks for the good vid of rebuilding the D44, I will add the tools you used to my list of things needed for my swap project!!

Just wanted to say thanks I learned a lot from this video you should make more videos

Excellent video. Makes a change to watch a well flowing video with just the right amount of talking. I have a Salisbury diff in my Land Rover, which appears very similar. I am about to add a diff lock, and the thought of setting the carrier afterwards was a little daunting. I assume in most instances you set the pinion up at the required preload and just move the carrier left to right in order to get the desired pattern.

Outstanding video, thanks for the insight, even for those of us " Veteran mechanics ", small details get fuzzy over time.

Excellent. thank you. I am doing this for the 1st time on a 1996 jeep that blew its inner pinion bearing.

love this Vid, I really like that puller, perhaps the best one i have seen, I also love your T176 Jeep gear box rebuild, cheers for the vids