I have a '63 544 with the original axle, a 4.11 Dana 27. How many splines do the axle shafts have where they fit into the differential?
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I'm JohnMc, and I approved this message.

Well, here's the fruits of my latest eBay find: Item number: 8002888715

It's for a Dana 27, it has 10 splines, it's for the correct gear range (3.92 and up numerically) for my 4.10 gears. I guess if for some reason it doesn't fit I can probably get most of my money (less shipping) back selling it to Jeep folks.

With the added HP and the rear sway bar it's hard to put power down around a corner with the standard diff in there now.

Anybody have any tales of success doing dufferential swaps yourself? Or is this really something best left to professionals? I don't get a warm and fuzzy feeling reading about shimming, case spreading, gear clearances, etc. At least in terms of my doing it myself and ending up with anything other than a howling set of gears eating themselves.
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I'm JohnMc, and I approved this message.

I think that'll work fine for you... good score.

As for installing it, I've not done it. But there is no need for case spreading. Just have to pull the axles out. Shimming it up right though... that's something I'd leave to professionals unless you have the tools and know how. Probably not too hard, just need the right measuring tools to get it right.

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-Matt I ♥ my ♂

Are you *certain* it's got a Dana 27? If so, George is correct.. it will have 10 spline axles as do all Dana 27s. But the Salisbury axle as found in '66 and older 122 wagons (wagons only) look almost identical to the dana/spicer 27, but the bits within are not quite the same. And I think a 544 of your vintage *might* have a salisbury unit. If so, it's got something wierd like 17 or 18 or 21 spline axles.

But if you are certain it's a Dana 27, it'll have 10 splines.


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-Matt I ♥ my ♂

It has a sheet metal cover bolted on the back side, that means it's a Dana, doesn't it? I think the older B16 engined PV's had a different axle, I *think* the B18 engined ones have Dana 27's.

Thanks for the info, the '10' is what I wanted to hear.
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I'm JohnMc, and I approved this message.

In looking at what parts I have left that I could find... I can confirm that the Salisbury unit axles have 18 splines. and both would have a sheet metal cover.

I'm guessing you have 10 spline dana unit though, but can't be sure. WHat is the information needed for anyhow? I think you'd know for sure if pull that cover off see whats stamped on the ring gear. I'll also check my books when I get home later. If you are thinking of buying expensive non-returnable parts, I'd hate to hear they don't fit... best to be sure.

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-Matt I ♥ my ♂

My Road & Track book says a 544 ('64) has 4:10 gears. I don't think that ratio was used in the Salisbury gear sets, so I'm now almost certain you'll find 10 spline Dana/spicer 27 axles back there.



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-Matt I ♥ my ♂

Would it be the same as a 122? I have a couple axles in the garage. They have 10.
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George Downs Bartlesville, Heart of the USA!

I'd *think* so. At least the contemporary 122's (pre 66).
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I'm JohnMc, and I approved this message.