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More Dana Spicer Fun: Front Chromoly Axle Shafts

JeepOfTheseus

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An unfortunate follow-up to my rear axle issue. I ordered the front chromoly axle shaft kit which is listed as fitting the "Dana 44 w/Narrow Open Diff", i.e. Overland, i.e. mine. On Dana's site, it is described as fitting "Dana 44™ AdvanTEK® Open Differential" and does not call out as being used with "FAD Removal". My understanding is that this means the kit retains the FAD.

Admittedly, Dana only states fitment for JL on their summary page, however if you look at the individual axle shaft parts, they also say 10044431 only fits JL, however the actual product page for that says it fits Gladiator...so what can you even believe?

One last bit of confusion...the number stamped on the shaft, 10044425, only points to the inner shaft product page which oddly only lists JLs again.

Long story short, at the end of these shafts...instead of it ending immediately at the edge of the splines, there is a little nub that is retained. My guess/understanding is this sits inside the FAD coupler bushing (?) so the shaft is actually "connected" and isn't just flopping around instead the axle tube even if the splines aren't engaged. The one on the chromoly axle is larger than my original, and as such...the shaft will not properly seat all the way in.

I'm working with @Northridge4x4 again to resolve this, but Dana has been incredibly slow to respond...in fact, because Northridge tried putting pressure and contacting twice in a row, it put the ticket at the end of the queue :mad:

I'm wondering if anyone has even purchased and/or tried installing these before. I'm trying to figure out if:
1.) They just sent me the wrong part entirely
2.) They sent me the shaft that is intended for removing the FAD and therefore the bushing (assuming there is a difference)
3.) They don't actually make these for the JT narrow-axle and this is a lost cause

I also don't get why they seemingly included some parts of the FAD Removal kit - they provided the 4 bolts and the gasket (not the actual block-off plate or coupler). I'm not sure why I'd need to disassemble and use a new gasket if I'm retaining the FAD anyways.

Jeep Gladiator More Dana Spicer Fun: Front Chromoly Axle Shafts IMG_6928


Jeep Gladiator More Dana Spicer Fun: Front Chromoly Axle Shafts IMG_6927
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JeepOfTheseus

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Well, Max at @Northridge4x4 was spot on: he called me shortly after seeing this and suggest removing the plastic bushing in the intermediate shaft. This despite Dana’s site saying the bushing is used if retaining the FAD.
Turns out, that bushing is exactly the difference in how much is machined off on the stock vs, chromoly axle:



Jeep Gladiator More Dana Spicer Fun: Front Chromoly Axle Shafts IMG_7014
Jeep Gladiator More Dana Spicer Fun: Front Chromoly Axle Shafts IMG_7015
 
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JeepOfTheseus

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Update: finally got it on the road today. I tackled this in conjunction with a wiring/light project, so it was sitting for a little over a week. Everything works great: FAD engages/disengages properly, no clearance or vibration issues...all it took* was removing that bushing.

*If you have RockHard 4x4 front LCA skid plates, it makes removing the FAD skid plate and housing a bit challenging. It is possible to do it without loosening/removing the LCA skid, but it was tight.
 

KayboKabuk

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I am having a similar issue. I have a Rubicon, so I have the wide track with the locker. I didn’t see a bushing in the intermediate shaft though.
 
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JeepOfTheseus

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I am having a similar issue. I have a Rubicon, so I have the wide track with the locker. I didn’t see a bushing in the intermediate shaft though.
Do Rubicons/yours come with FAD? My understanding is the bushing is only applies in that scenario: to disengage the passenger axle.
 

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KayboKabuk

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Yes. The Rubicon also has the FAD.
 

KayboKabuk

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Yeah. Or makes no sense. I read in another forum where a guy who ran into the same issue had a machine shop machine the chromoly axle down to match the factory axle.
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