Nissan Frontier (D22) REAR Solid Axle Swap (SAS) with a Dana 44 from a Isuzu Rodeo/Honda Passport 93-97.

 (updated 4/2009)

The Dana 44 was used in the rear of the Isuzu Rodeo and Honda Passport. It uses a unique Pinion bearing and crush sleeve un like the standard dana 44 of the 70-90s dana 44. This is a great axle swap for W/D22 (Nissan Xterra and Frontier). The ring gear is smaller than the H233. But has more locker choices and lower gear options and Disc brakes.

Dana 44 Axle prep

The Honda/Isuzu Pinion does use most of the old popular dana 44 parts. The ring has to be thick or use a new carrier. The pinion is the same. The pinion bearing is Isuzu only. Its much bigger.  The Pinion outer diameter is smaller, but the inside diameter appears the same. There is also a crush sleeve. The pinion seal is the same as old style.

Once I removed the tone ring for ABS the carrier looks normal.

Normal Dana 44 on left (5.13) and Thick gear on right 4.55 (Honda/Isuzu)

The bolt holes had to be enlarged for the new Thick ring gear. The pinion seal is the same as the popular Dana 44s. They were drilled out to accept the new ring gear bolts.

 

Bearing and seal replacement.
If you want to change the wheel seals you have to press the bearings off the axle. We made a jig from some angle iron and pressed off bearing. We just cut off the slug that holds the bearing on. There was also a snap ring to remove.

 

Just cut and pound off.

  

Then press old bearing and slug off.

All clean.

Press on new bearing, the press on new slug
 

Parking Brake

Parking brake cross member. It uses the honda/isuzu bracket on some 1.5" tube. No modification to the Nissan first part. Its the same size and bolts on Honda mechanism.

 

Driveshaft

The one piece shaft was made 3" longer by a local shop. This is an upgrade from the stock 2 piece.

 

Shock mounts and U bolts.

Reused all old Nissan U bolts, plates and shocks.