Dana 44a Rebuild - Page 2 - JeepForum.com
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post #16 of 45 Old 10-18-2016, 12:06 PM
StPaul59
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Sorry for all the questions, but I'm about to tackle this and want to cover everything.

One last question.. Do I need to remove the pin when pulling the whole thing out gears and all? Or does that stay in there.

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post #17 of 45 Old 10-18-2016, 12:30 PM
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Originally Posted by StPaul59 View Post
One last question.. Do I need to remove the pin when pulling the whole thing out gears and all? Or does that stay in there.
Cross shaft must come off, otherwise you can't push in the axle shafts, then remove c-clips and pull shafts out. Without pulling out shafts, carrier isn't coming out.
When removing the cross shaft lock pin/ bolt, be VERY VERY careful! If it feels even slightly stuck - STOP! Then heat up the area on the carrier with a MAPP torch or propane torch where the securing pin/bolt goes in, and try again. If it snaps, it is a real big pain to remove.
It is not uncommon for it to snap, and it is not uncommon to destroy the carrier removing the snapped pin.

When putting things back together, ALWAYS use a new cross shaft securing pin/ bolt.


You were asking about pounding the big gear, you mean ring gear? You don't need to remove the gear for bearing replacement. If you're doing an R&P swap at the same time, unbolt the ring gear bolts about halfway, then use a deadblow hammer or a regular 5lbs. hammer to carefully pound off the ring gear. Work in a criss-cross pattern.
If new ring gear does not install easily, heat up the ring gear in an oven to something like 300-350F, and place the carrier into the freezer for an hour or so.


One suggestion for removing the carrier if it is stubborn to come out of the axle housing; this way you don't need a case spreader.
1. Loosen the carrier bearing cap bolts about halfway out.
2. Put a ratchet strap around the carrier (as close to centerline as possible), secure the ratchet strap hooks to ie. hitch receiver, hitch, or rear bumper (wherever you can)
3. Start to tighten the ratchet strap
4. Watch the carrier come out

You want the carrier bearing caps to be there to prevent the carrier completely falling out.


..and just as a reminder what I wrote before: if you can't find a carrier bearing puller for rent, no need to buy one. Just use a thin stainless steel 4.5" angle grinder cut-off disc, and very carefully cut almost through the bearing cone (pry of the bearing cage first). Once you're almost through, use a punch (or flathead screwdriver) and a hammer on the cone lip to whack it out.
I've removed about a dozen carrier and pinion bearings this way, not once have I cut into the bearing seat. Did I mention to cut carefully?
Also, installing new bearings is an easy job with a suitable diameter tube + hammer. It will not damage the bearing.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #18 of 45 Old 10-19-2016, 09:10 AM
StPaul59
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Good tips. The part about hammering on the ring gear, I was wondering what if anything to avoid hitting when getting the carrier back in.
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post #19 of 45 Old 10-19-2016, 09:54 AM
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Use a piece of sturdy wood (ie. 2x2 or 2x4), place it against the carrier in the center area (avoid hitting the cross shaft), and whack the carrier in with a deadblow. Works like a charm

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #20 of 45 Old 10-22-2016, 02:58 PM
StPaul59
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What about the track lok clips that fell out when I removed the carrier? Should there be one for each hole? And pushed all the way in?
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post #21 of 45 Old 10-22-2016, 03:50 PM
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There are four clips; two on each side. Did you actually check your track lok condition? It's more than likely you have failed parts on it, it's very common for one or more of the clutch pack discs to fail.


1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #22 of 45 Old 10-25-2016, 09:15 AM
StPaul59
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Got the carrier bearings changed, still have noise.. JY here I come.
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post #23 of 45 Old 10-25-2016, 01:10 PM
PolkaPower
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Quote:
Originally Posted by StPaul59 View Post
Got the carrier bearings changed, still have noise.. JY here I come.
Thrust washers often leave metal in the diff too.
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post #24 of 45 Old 10-26-2016, 06:40 AM Thread Starter
Boone96ZJ
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if your trak-lok fell out and was broken, you had bigger problems than bearings going on.

96 5.2 242 3" 32x11.5
http://www.jeepforum.com/forum/f13/1996-grand-cherokee-laredo-5-2-a-2570290/
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post #25 of 45 Old 10-26-2016, 07:52 AM
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Originally Posted by Boone96ZJ View Post
if your trak-lok fell out and was broken, you had bigger problems than bearings going on.
Well actually, it is a very common issue on the dana trashloks for them to fall apart and fall out of the carrier in pieces. I've personally seen it on multiple d35, d44 and d44a LSDs. I would be more surprised to find one with no broken plates

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #26 of 45 Old 10-26-2016, 08:15 AM
StPaul59
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My trac lok actually worked great and still works . Its like a one legged horse that can still run a race.
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post #27 of 45 Old 10-26-2016, 09:06 AM
StPaul59
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So if anything came out if the carrier when I pulled it, that would be a problem then? They looked like they fit each hole where it says trac lok perfectly, so I put them back in there..
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post #28 of 45 Old 10-26-2016, 09:17 AM
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Originally Posted by StPaul59 View Post
So if anything came out if the carrier when I pulled it, that would be a problem then? They looked like they fit each hole where it says trac lok perfectly, so I put them back in there..
If the LSD is in good condition, nothing should fall out. If the clutch packs are worn, they will get flatter and have no (or very little) spring tension on them. That will cause the LSD to not grab much at all, and it also leads to one or more of the clutch pack ears to crack, or clutch discs to crack.

It's not really a problem, just a worn LSD which needs a rebuild kit.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #29 of 45 Old 10-26-2016, 12:08 PM
StPaul59
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That must be what's making noise then. Those pieces fit perfectly into the holes into the carrier just like they belonged. So stupid me, just put them back as I was pressed for time. Ill see if I can pull them out and quiet the thing down.
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post #30 of 45 Old 10-26-2016, 12:18 PM
Timo_90xj
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How many miles on your d44a? I would probably just buy a set of new Spicer clutch packs and swap them in. That is, if the stock LSD is all you need.
You will be surprised how big a difference there is between the old clutch packs and the new.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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