Yukon Gear Master Overhaul Kit For Dana 44 Diff w/ 19 Spline

If an older Dana 44 has started to howl on decel, clunk when you get on and off the throttle, or leave a wet ring of gear oil around the pinion yoke, the bearings and shims inside the housing are usually what has given up. Yukon's YK D44-19 is the master overhaul kit for Dana 44 differentials built around 19-spline axle shafts, the spline count found in many older full-size GM and Ford half- and three-quarter-ton 4x4 front axles and other vintage Dana 44 builds.

What a master overhaul kit does in a Dana 44

A Dana 44 is a carrier-type axle: the pinion rides on two tapered roller bearings in the housing, and the carrier with the ring gear rides on two more at the side bearing caps. Pinion depth, pinion bearing preload, carrier preload and backlash are all set with shims, and every one of those settings depends on bearings that have not worn. Once the races pit or the rollers wear, the pinion walks under load, the gear contact pattern shifts toward the tooth edge, and the gears start to whine. Per Yukon, this kit includes carrier bearings and races, pinion bearings and races, a pinion seal, a complete shim kit, ring gear bolts, a pinion nut, thread locker, marking compound with a brush, and the cover gasket. The bearings and races are Timken.

Symptoms that call for this kit

• Whine or howl that changes between accel and coast, a classic sign of worn pinion bearings or lost preload
• A growl or rumble that rises with road speed, from worn carrier bearings
• Clunk or extra driveline lash when shifting from drive to reverse
• Gear oil leaking from the pinion seal and slinging onto the driveshaft
• Metal glitter or bearing cage fragments on the drain or fill plug
• Gears that were never set up correctly after a previous ratio swap

How to confirm before you buy

Pull the cover and drain the oil into a clean pan; fine paste is normal, chunks or cage pieces are not. With the wheels off the ground, grab the pinion yoke and try to move it up and down and in and out. Any free play there means pinion bearing preload is gone. Spin the carrier and listen for roughness, then paint a few ring gear teeth with marking compound and check the pattern. A pattern that has walked toward the toe or heel, or a pinion that rocks, means a full bearing and shim job, which is exactly what this kit is for. If the ring gear teeth are chipped or scored, plan on a new gear set at the same time, such as the Yukon 4.88 Dana 44 standard rotation gear set, since the overhaul labor is the same either way.

Fitment

This kit is listed by Yukon for Dana Spicer 44 differentials with 19-spline axles. The Dana 44 was built for decades in front and rear, standard and reverse rotation versions with different shaft splines, so the spline count is the quickest way to tell the generations apart. Pull an axle shaft and count the inner splines before ordering; if your shafts are 30-spline, this is not your kit and a sibling such as the Yukon Dana 44 master overhaul kit or one of the Jeep-specific kits will match instead. Also confirm the axle tag reads Dana or Spicer 44. If you are unsure, send us the year, VIN and the tag numbers from the axle and we will check it before it ships. Browse the rest of our axle and transmission rebuild kits for other housings.

Install notes

• Mark the bearing caps left and right before removal; they are machined with the housing and must go back on the side they came from.
• Pulling the old carrier bearings without damaging the shims is much easier with a clamshell puller like our Dana 44 carrier bearing puller.
• Set pinion depth first, then pinion bearing preload, then carrier preload and backlash, and verify with the marking compound included in the kit.
• Use the supplied thread locker on the ring gear bolts and torque them in a cross pattern; use a new pinion nut rather than reusing the old one.
• Refill with 75W-90 or 75W-140 gear oil, adding friction modifier if the axle has a clutch-type limited slip. New gears or bearings should get a gentle break-in before towing or heavy trail use.

Front axles with 19-spline outer stubs often need hub work at the same time; the Yukon Hardcore 19-spline locking hub set is built for these axles. Setup is precise work: if you do not have a dial indicator and an inch-pound torque wrench, have a driveline shop do the shimming.

How do I know my Dana 44 is the 19-spline version?

Pull an axle shaft and count the splines on the inner end that goes into the carrier. This kit is for 19-spline shafts. If you count 30, you need a different Dana 44 overhaul kit. Send us the year, VIN and axle tag if you want us to confirm before ordering.

What is included in the YK D44-19 kit?

Yukon lists Timken carrier bearings and races, pinion bearings and races, a pinion seal, a complete shim kit, ring gear bolts, a pinion nut, thread locker, marking compound with a brush, and the differential cover gasket. Gears, spider gears and axle shafts are not included.

Can I use this kit when installing new ring and pinion gears?

Yes. A gear swap uses the same bearings, shims and seal, so most builders install a master overhaul kit with every new gear set. Order the gear set to match your axle's rotation and carrier.

What gear oil should I use after the rebuild?

Use 75W-90 or 75W-140 gear oil. If the axle has a clutch-type limited slip, add friction modifier unless the oil already contains it. Check the level at the fill plug after a short drive.

Is this a do-it-yourself job?

It can be if you have a dial indicator, an inch-pound torque wrench, a bearing puller and a press. Pinion depth, preload and backlash all have to be set and checked. Without those tools, a driveline shop is the safer route.