I want to build a costum axle for my vitara. I want to use a dana 44 axle and but a sidekick rear diff in it. My biggest problem is that the rear diff has 26 spline axles and a dana 44 has 27 spline axles...

How could a solve this problem? Respline the 27 axles to 26 axles or does there exist a adjustment so i can put in a diff with 27 splines?

Why would you want to put a Sidekick diff in a Dana 44?  That just doesn't make much sense to me.

I want to keep my rear axle so i must have the same R&P's. I've allready invested in a rear locker and the 4.30 R&p is also here so i don't want to trew that all away.

Dave,

I'd suggest either 4.88 or 5.12 for the D44 and then get a kick/trac r/p to match. other choices for the D44 are 5.38 or 5.89. The 5.38 does exist in certain trac/kick diffs, so that's another option.

IMO the 4.30 you have now is too tall a gear anyway ...

I have a sam gearbox, thats why the R&P is that large.
(I could drive a 38" tire and rev's as much as stock gearing with stock tires if i would use the 5.125 gears.)

Seriously - you will be far better movig the D44 and the Kick Diff to a common gear ratio, than trying to fit a Kick diff into a D44 axle.

Yes, i know. A 4.27 gearing for a dana 44 does also exist. But that would be probably not exact enough to fit with a 4.30 in the sidekick axle?

I have a sam gearbox, thats why the R&P is that large.
(I could drive a 38" tire and rev's as much as stock gearing with stock tires if i would use the 5.125 gears.)

ah ... didn't know that ... 

4.88's are *only* another 13% lower than the 4.30's ... (I believe that's a 99+ AT with 2.0l)

I 'm thinking about buying a rear dana axle to. Will make my life a little bit easy'er i think.
Mayby I thake 4.10 r&p's in it so i can reduce my gearing even more with my sam case (a 4.16 or 6.1)

What are the best axles to use? Wagoneer axles ? Do they have correct bolt patterns?

waggy axels are pretty good choice if your set on 44's ... get around a '78 (pass drop and flattop knuckles) and they measure out about 2" wider than a kick (60.5" waggy vs 58" on a kick) ...

Do a search as I posted some details about 27 spline axles and full floaters. If you have a Kick with a rear ARB locker you can get replacement sidegears for 27 spline axles as well as D44 30 spline axles. I have physically seen these myself at ARB HQ in OZ.