How to Deep Clean a Dan Wesson 44 Revolver

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January 10, 2026

In this video

Full Step-by-Step Dan Wesson 44 Disassembly, Cleaning, and Reassembly Guide

This Dan Wesson 44 Magnum came from the same estate sale as the Glock 29 deep cleaning. It rode hard in Montana backcountry and it shows. The barrel nut alone tells you this revolver lived a life.

This guide is written like a bench manual. Not a transcript.

You can follow it with the video or use it standalone.

Safety and bench setup

Video: https://youtu.be/7hEL7NUBXSw?t=44

Verify unloaded
Remove all ammo from the area
Eye protection on
Parts tray ready
Good lighting, no clutter

Tools and supplies

Video: https://youtu.be/7hEL7NUBXSw?t=54

You’ll need:

Punches and roll pin punches
Hex and Allen bits
Feeler gauge (0.006 inch)
Dan Wesson barrel nut wrench
Bore cleaning cable or rod, brushes, patches
Ultrasonic cleaner (recommended)
Controlled heat source

Affiliate resources (listed once, like a normal manual):

Fix It Sticks kits and punches: https://trb.fyi/fis
Otis rods, brushes, patches: https://trb.fyi/otis
Aegis cleaner and lube: https://trb.fyi/boomlube (Use code boomlube for 10% off)

Step 1: Initial barrel inspection

Video: https://youtu.be/7hEL7NUBXSw?t=73

Goal: confirm the barrel is worth your time.

Inspect the bore visually
Run a brush to loosen fouling
Patch until you can see the bore surface
Expect lead fouling on estate revolvers

Stop if you see cracks or deep pitting that looks structural.

Step 2: Diagnose the barrel nut problem

Video: https://youtu.be/7hEL7NUBXSw?t=118

Normal Dan Wesson barrel system:

Remove barrel nut
Slide shroud off
Unthread barrel

If the nut is damaged, rounded, or seized:

Shift focus to the barrel-to-frame threads
Work penetrating lubricant into the junction from the chamber side
Let it soak

Step 3: Build the custom barrel tool

Video: https://youtu.be/7hEL7NUBXSw?t=173

This tool lets you spin the barrel out from inside the shroud.

3/8-16 x 9 inch bolt
Washer
Copper washer trimmed to fit
Electrical tape to protect bore
Double-nut the rear so nothing slips

Key detail: trim the copper washer so it spins with the barrel and does not bind the shroud.

Step 4: Remove barrel and shroud

Video: https://youtu.be/7hEL7NUBXSw?t=244

Prerequisite: Revolver unloaded. Barrel junction soaked as needed.

Apply heat to the frame, not the barrel
Use the internal tool to start the barrel moving
Once it breaks free, run it out steadily
If the shroud sticks, use light tapping to free it
Remove shroud, then remove barrel

Inspect barrel threads and frame threads. Clean thread debris before reassembly.

Step 5: Front sight removal

Video: https://youtu.be/7hEL7NUBXSw?t=324

Use the 0.050 Allen bit
Loosen screw
Rock sight rearward and lift out
Inspect for rust underneath

Step 6: Grip removal

Video: https://youtu.be/7hEL7NUBXSw?t=361

Use the 5/32 bit
Remove grip screw
Slide grip off tang

Step 7: Capture the mainspring

Video: https://youtu.be/7hEL7NUBXSw?t=383

Use the 5/64 bit to remove the mainspring retaining screw
Cock the hammer
Thread the screw into the mainspring guide to capture the spring

Step 8: Rear sight disassembly

Video: https://youtu.be/7hEL7NUBXSw?t=414

Drive out the roll pin above the cylinder using a 1/16 roll pin punch
Hold the sight down since springs are underneath
Remove the flathead elevation screw
Remove springs
Remove the blade (0.050 bit). Tap lightly as needed

Step 9: Hammer removal

Video: https://youtu.be/7hEL7NUBXSw?t=508

Drive hammer pivot pin with a 9/64 brass punch
Hold trigger back
Rock hammer out

Then disassemble hammer:

Drive strut pivot pin with 1/16 punch
Remove strut, plunger, spring

Step 10: Trigger guard and trigger removal

Video: https://youtu.be/7hEL7NUBXSw?t=585

Depress trigger assembly latch using a 3/16 brass punch
Rock trigger guard forward and remove
Control the hand, connector, and small spring
Remove latch and spring (1/16 roll pin punch)
Drive trigger pivot pin (3/32 punch)
Remove trigger and trigger return spring and guide

Step 11: Crane and cylinder disassembly

Video: https://youtu.be/7hEL7NUBXSw?t=666

Prerequisite: Trigger guard removed.

Remove crane lock
Unscrew ejector rod
Remove extractor
Remove crane
Remove bolt plunger and spring
Separate cylinder from crane
Remove ejector rod bushing and spring
Remove crane latch retaining screw with 0.050 bit
Remove latch and latch spring

Step 12: Frame internals removal

Video: https://youtu.be/7hEL7NUBXSw?t=773

Cylinder alignment ball:

Remove screw
Remove spring
Remove ball

Firing pin removal (cylinder open): https://youtu.be/7hEL7NUBXSw?t=802

Drive out firing pin retaining pin (1/16 punch)
Drive firing pin out from the rear (9/64 punch)
Remove bushing

Mainspring removal: https://youtu.be/7hEL7NUBXSw?t=835

Remove mainspring retaining screw (5/64 bit)
Control mainspring guide with pliers
Remove guide and mainspring carefully

Step 13: Ultrasonic cleaning

Video: https://youtu.be/7hEL7NUBXSw?t=870

Clean frame and components
Dry thoroughly, especially holes and channels
Protect metal immediately with light lubrication

Reassembly overview

Follow the same system order:

Frame internals
Crane and cylinder
Trigger group
Hammer
Sights
Grip
Barrel, gap, shroud, nut
Final clean and function check

Step 14: Frame reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=912

Cylinder alignment ball:

Ball first
Larger spring next
Screw flush
Verify free movement

Firing pin installation: https://youtu.be/7hEL7NUBXSw?t=955

Install firing pin
Install spring
Install bushing with relief cut up
Install retaining pin

Mainspring installation: https://youtu.be/7hEL7NUBXSw?t=1006

Insert mainspring
Insert guide with hole side down
Compress and install retaining screw

Step 15: Crane and cylinder reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=1044

Install crane latch spring and latch
Install latch retaining screw
Install ejector rod bushing and spring in correct orientation
Install cylinder
Align extractor tabs and install extractor
Install ejector rod
Install bolt plunger and spring
Install bolt into frame
Install crane and crane lock

Step 16: Trigger group reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=1408

Install trigger return spring on guide
Seat guide correctly in trigger guard
Use punch to hold alignment, then replace with pivot pin
Install trigger assembly latch spring and latch
Install roll pin
Assemble hand, connector, and spring
Use a rubber band to hold parts during trigger guard install
Seat trigger guard and lock it with the latch

Step 17: Hammer installation

Video: https://youtu.be/7hEL7NUBXSw?t=1485

Assemble strut plunger and spring
Install into hammer
Install strut and pivot pin
Install hammer into frame while controlling trigger position
Install pivot pin
Release captured mainspring and return screw to frame

Step 18: Rear sight reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=1529

Reinstall detent and spring
Install blade and retaining screw
Use grease to hold elevation springs in place
Pre-start roll pin, align holes, drive pin flush
Install elevation screw

You will re-zero at the range.

Step 19: Grip install

Video: https://youtu.be/7hEL7NUBXSw?t=1661

Slide grip onto tang
Install grip screw
Dry fire while tightening so you don’t bind the mainspring

Step 20: Barrel gap, shroud, and barrel nut

Video: https://youtu.be/7hEL7NUBXSw?t=1718

Install front sight on shroud
Thread barrel into frame most of the way
Set barrel-to-cylinder gap with a 0.006 feeler gauge
Install shroud onto frame pin with no gap at the frame
Install barrel nut carefully to avoid cross-threading
Snug barrel nut with the correct wrench

Step 21: Final cleaning and range prep

Video: https://youtu.be/7hEL7NUBXSw?t=1779

Brush bore
Patch until clean
Light oil pass through bore
Wipe exterior
Bore sight so you land on paper at the range

FAQ

What is the correct Dan Wesson barrel-to-cylinder gap?

This guide uses 0.006 inch with a feeler gauge during barrel setup. https://youtu.be/7hEL7NUBXSw?t=1718.

What if the barrel nut is damaged or rounded?

Use penetrating lubricant, soak time, and the correct barrel nut wrench. If the nut is compromised, replace it.

Do I have to use an ultrasonic cleaner?

No. It saves time and reaches tight areas. If you skip it, plan for more manual scrubbing.

Could a cylinder drag line be from someone spinning the cylinder?

Yes. A drag line can happen from normal operation. Aggressive spinning can make it worse. Check lockup and timing consistency.

What should I check after reassembly before live fire?

Cylinder opens and closes smoothly
Lockup feels consistent
Trigger resets correctly
Firing pin movement feels normal
Barrel gap is correct

Glock 29 deep cleaning and reassembly: https://trb.fyi/how-to-disassemble-and-reassemble-a-glock-29-full-step-by-step-breakdown/
Glock 43 disassembly and reassembly: https://trb.fyi/how-to-disassemble-and-reassemble-a-glock-43-step-by-step-full-breakdown/
Dan Wesson Model 15-2 deep cleaning: https://trb.fyi/step-by-step-how-to-deep-clean-and-maintain-your-dan-wesson-model-15-2/

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Credit: Jason Schaller
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About the Author: Jason Schaller is a former FFL holder and founder of Eagle Eye Shooters Supply in Helena, MT, where he provided professional gunsmithing services and guided customers on all aspects of firearms ownership. Today, he teaches DIY gunsmithing at The Rogue Banshee and serves as a Chief Instructor at Freedom Crew University. With over a decade of hands-on professional experience with firearms and nearly 30 years in IT, Jason also holds top cybersecurity certifications including CISSP, CISA, and CRISC. When he’s not geeking out, he’s helping others build self-reliance, critical thinking, and firearms proficiency through real-world content.

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