The CJ-5 I bought last year had been modified to accept a GM 350. I really liked the way they put together the engine mounts, so I chose to reuse the mounts and then modified my frame to accept the mounts.

To make the mounts, I took the standard buick v6 mounts and removed the rubber blocks, leaving only the steel.  Then, I cut and welded some 3×3 square tubing to the mounts.  

To make the holders that are welded to the frame, I used some recycled angle iron and added side braces to create the triangular look.  I look this setup much better than what I did in my first jeep. 

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These shots show the painted frame with the Dana 44 rear and Dana 30 front painted and attached.

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With my Dana 44 all taken apart (See article below), it was time to put everything back together.  One aspect I have left out of the rebuild process is the importance I placed on using the appropriate language to assemble and disassemble the R&P properly; lets just say I'm glad my children weren't about.

Gathering tools and parts

In terms of parts, I needed to gather a rebuild kit, a locker, and axle kits.  Using Craigslist, I found a locker for 3:73 gearing locally for $325.  The rebuild kit I got at half price from a jeeper in Bend, Oregon. The axle bearings, cones, and outer seals were purchased online through Tellico4x4.com. The inner axle seals I purchased at Schucks. At first, when I realized I had forgotten to order these (oops), I went to tellico's website.  The seals themselves were around $5 a piece, but the cost for shipping was going to more than double the price.  I thought that was ridiculous.  So, I dropped by the local Schucks to see what it would cost to get the seals (I figured they would have to order them).  Well, to my surprise, they had them in stock! $10 later, I was out the door with them. 

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The Goal .. take apart my Dana 44 housing and install a Detroit Locker along with new bearings and seals.  Sounds easy enough, right?

When building my last jeep, I did not have to rebuild either of the axle housings.  In the rear I had a Dana 44 from a mail jeep.  Mail jeeps come with detroit lockers:  note that the housing is a little narrower than a standard jeep by approx 2".  To fix this, you can have some shims machined that will allow you to use standard flanged jeep axles.  

Fast forward to the new jeep.  I had a Dana 44 I knew nothing about and a detroit locker I wanted to install inside it.  I figured this would be a good opportunity to learn about ring and pinions; and, learn a thing or two I did!

The First Issue – Broken teeth

Naturally, the first step was to pull off the housing cover and examine the condition of the gears.  Unfortunately, the news was not good.  I quickly discovered that I had a very broken tooth on the ring gear.

Interestingly, there was no evidence of broken pieces in the oil.  This lead me to suspect that the previous owner may have discovered the damage while changing the gear oil and 'forgotten' to mention it to me.  Also, once I pulled everything apart, I would also find the pinion gear broken as well.  

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