BOM & brakes.......

tailgunnerex

Well-Known Member
Joined
Nov 24, 2008
Location
fuquay varina
I have a 2004 Wrangler (X) that was supposed to have been a Willys package. Everything in the package was there except the Dana 44 rear. Was told by those more in the know than I that it was a rip commonly known as a "Dealer Prep Package", in other words, it has all of the eye candy (seat covers, stickers (some), etc.) but doesn't have the guts (i.e., heavy axle) that would have been in the package if it had come from the manufacturer with the same package.
Well, I found a salvage yard 44 out of a 2006 Unlimited but, unlike mine (Dana 35 w/drums), it has disc brakes. First thing I need to know - what changes have to be made to my existing brake system to be able to make use of the disc set up on the 44 and second - where the hell is the BOM? I found a host of numbers/letters on the axle tubes and ran all of them - in part and whole - on Dana's web site in the attempt to identify what all I have here but all kicked out as not being an identifiable BOM. I know it's 3.73's (by the tag) with some sort of locker/limited slip (spun the axle by hand). Will open tomorrow, cover gasket looks factory.

Any help out there?
 
tailgunnerex said:
I have a 2004 Wrangler (X) that was supposed to have been a Willys package. Everything in the package was there except the Dana 44 rear. Was told by those more in the know than I that it was a rip commonly known as a "Dealer Prep Package", in other words, it has all of the eye candy (seat covers, stickers (some), etc.) but doesn't have the guts (i.e., heavy axle) that would have been in the package if it had come from the manufacturer with the same package.
Well, I found a salvage yard 44 out of a 2006 Unlimited but, unlike mine (Dana 35 w/drums), it has disc brakes. First thing I need to know - what changes have to be made to my existing brake system to be able to make use of the disc set up on the 44 and second - where the hell is the BOM? I found a host of numbers/letters on the axle tubes and ran all of them - in part and whole - on Dana's web site in the attempt to identify what all I have here but all kicked out as not being an identifiable BOM. I know it's 3.73's (by the tag) with some sort of locker/limited slip (spun the axle by hand). Will open tomorrow, cover gasket looks factory.
Any help out there?
Click to expand...
The BOM will be 6 numbers starting with a "6". It's stamped lightly on the tube just to the right of the diff. Clean it up with a wire wheel and you should see it. Also should be on the tag, I think. What numbers did you find?
 
Sorry so long, been eatin'..........
The numbers I found on the passenger side tube are:
C47 DR2005806 AAU5U 7USM260 1M1
Drivers side tube I found the following:
AAU5015USM260 2M2
That's everything, other than what's on the diff cover. Even did some scraping and wire brush work. Since the axle is pretty new it's easy to see any stamping and this is all I could find after rolling it over a time or two.
Almost forgot, checked the tags (there are two) one has the weight, type and quantity of gear oil and modifier to use and the other has the gear ratio along with four or five other numbers that I couldn't relate to anything.


foreman1063 said:
The last year I can find on Dana's site is 2001 TJ rear 44. the BOM is 606565-4. Is that close to any numbers you have?
Click to expand...
 
Not sure about those numbers but look in this diagram to see exactly where I'm talking about. When I say lightly engraved I mean light. Clean it up good and they should be there.


ai22.photobucket.com_albums_b349_foreman1063_misc_BOM.gif
 
Here's the positioning of what I found
C 47
DR 2005806 (in area number 1) AAU 7USM260 1M1 (in area number 2, BOM)

As you can see there is no hyphenated number at the end of the sequence. The other numbers were on the left (driver's side) tube.
Maybe there have been changes since '01 in the layout. I will try to go back to teh Dana web site and run the area #2 numbers as a BOM and see what pops up.
 
Thanks, I've got the e-brake cables that came with teh '06 axle and the salvage yard is going to be sending me the mounting bracket for the ends of same where they come together with the operating cable from the pull lever.
I had heard in the past about the porportioning valve needing to be replaced/removed but couldn't remember it. If I recall correctly they said to remove it as it was not required for the power brakes. Other folks have said the master cylinder needs to be replaced, I'm just not sure what the real requirements are, is there a definitive source for this info?
 
I have an '01 that had drums and I ended up purchasing a Rubicon Dana 44 w/ disc brakes. I removed the o-ring from the stock proportioning valve, and had no problems whatsoever. Pedal may have been a tad bit softer, but braking was better than it ever had been before. Best mod i've done to the jeep since I had it.

Easy to try, if you don't like the way it feels, put the o-ring back in, no sense not testing it out (free to do). I could stop my jeep on the steepest of inclines, at anytime while out in Moab w/o any problem on 35's. In the rain, on the road, still no problem. I've read all the stories about people spinning around and losing control, but I've yet to ever see the slightest chance of that happening. I'd go that route and leave the M/C and booster alone until you try that first. You shouldn't have much problem at all. I'd run it in a heart beat (and have).

J.R.
 
'Prechate.......
I'll give that a try before i start in to buying and swapping parts I think.
Don't suppose you can shed any light on the BOM issue, eh? I just got back from teh Dana-Spicer web site and the newest thing showing that I could find is '02 for BOM's.
 
You know the gear ratio, you know it will bolt up, you know it more than likely has a LS in it. I think your golden.
 
No real worry, just wanted to be able to sort out the guts via the BOM. I'm still going to verify the ratio by spinning and the carrier by opening, cleaning out and inspecting it and the housing interior. Having the BOM, since I assume it's an all stock axle, and will be staying that way for a while at least, will give me the info I need to obtain parts/pieces should they be required. I'll keep log of it with the list of other odds and ends that make up this baby, after a while it gets a bit tuff to keep metal record of everything. For instance, I will not now go in and order stock brake parts as the rear end and brakes will be disc not drum (as original) and '06 not '04 (in case there might be a slight difference).

Geo
 
I think you won't have any trouble sourcing the correct parts for that axle. You should be able to go to family dollar and find a part for that thing...lol
 
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