Wheel Bearings turns into my axle rebuild thread - JeepForum.com
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Unread 07-19-2013, 05:37 PM   #1
stageninja
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Wheel Bearings turns into my axle rebuild thread

First a little history...
When I bought my 1st "mechanics spcl." ZJ Ltd W/Up-Country Pkg. it had a "roar/whine".
I had carrier & pinion bearings installed in both axles from a reputable shop across from Lucas Oil Stadium during construction.
That ZJ totaled due to front end collision.
A week later, my wife finds duplicate ZJ "mechanics spcl." w/o Up-Country Pkg. from same Chrysler Dealer.
Get totaled ZJ as parts Jeep from Insurance co.
Transfer rebuilt rear axle & U-C Pkg. Along w/a cornucopia of parts from the wreck over the last 5 years.
Rebuild front axle myself as the d-30 from parts Jeep was destroyed.
Buy my wifes 2-wd ZJ & replace bearings in d-35 axle.

Present day; Since rebuilt d-44a axle started to roar I order outer wheel bearings as they weren't replaced in the initial rebuild & proceed to tear down to install.
All ready this far I decide to remove carrier and clean and inspect rear end.
Discover galled bearings and races, particularly on drivers side, of the rebuilt axle by a reputable shop with a state contract, that I transferred from parts Jeep.
order bearing kit from RRP.
At this point I started taking photos & will post them with-in the next 24 hrs.
I didn't intend for this repair to be a re-build thread but I guess it is now. I have discovered issues with the installation by a reputable...

More to come as I have to close garage & computer & go to work.

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-19-2013, 06:24 PM   #2
970001zj
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Unread 07-20-2013, 02:54 PM   #3
stageninja
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Here are the photos of what the shop did wrong and the results. All are taken from drivers side components.

1st 2 are the buggered factory shim. It appears the reputable shop beat it into place in the housing. This diff has 1 large shim each side of carrier, outside the outer bearing races.

The rest are pitted and galled races and buggered bearings.

I have cleaned and closed everything up for the week end as the machine shop I use closed Fri. about the time UPS arrived with the new bearing kit. I'll post more photos as I get them downsized.
axl_shim.jpg

2_buggerred_shim.jpg

galled_inner_race.jpg

pitted_outer_race.jpg

2buggered_bearings.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-20-2013, 06:08 PM   #4
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The next few photos are of the various parts cleaned and awaiting re-assembly after large p-bearing is removed and new one pressed on. There is also a photo of my custom cut gasket. It's a personal thing, I prefer a gasket to gasket goo & Lube Locker doesn't make one for the 44-a.
trac_l0k2.jpg   clean_trac_lok.jpg  
clean_parts.jpg

clean_case.jpg

cstm_diff_gskt.jpg

bearing_kit.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-20-2013, 06:26 PM   #5
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Here is the Trac-Lok with new bearings pressed on. If it looks a little frosty that's because I wrapped it up and put it in the freezer overnight to aid in getting the bearings on. I used the inner race from the old bearings as a pressing tool so as not to damage the bearing carriage. Then struck squarely with a dead blow mallet. After that thoroughly dried the carrier with paper shop towels and air.
new_brng_on2.jpg

new_brng_on.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-20-2013, 06:31 PM   #6
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Reaching a stopping point till Mon. when shop opens I wrapped the case and axle tube ends with shrink wrap.
clean_wrapped.jpg

wrapped_case.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-21-2013, 06:31 PM   #7
stageninja
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I did a couple of things today. I installed the pinion races and a new transfer case output seal since the shaft is out and the seal was leaking. The nicks inside the case I must assume came from that reputable shop.
pinion_race_1.jpg

pinion_race_2.jpg
xfer_case_seal.jpg

I also deburred the buggered shim. I know many of you are against reusing factory shims and I'm sure especially one that has been messed up by a prior servicing. I personally have had excellent luck with reusing the factory shims and always check the pattern before I close up and call it good. I will do the same thing here and with the d-44 & my d-30 having large outer shims, they make a good starting point to adjust without messing up the bearings. I was also careful only to debur and not compromise the integrity of the shim.

[ATTACH][ATTACH]deburred_shim_3.jpg[/ATTACH][/ATTACH]
deburred_shim1.jpg

deburred_shim_2.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-22-2013, 02:10 AM   #8
Timo_90xj
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Double- check your carrier bearing caps that you don't have spun the bearings inside them. D44a has a habit of doing that, and once the bearings have spun you may as well say bye-bye to the axle housing. Carrier bearing caps don't have enough clamping force, I've seen people take the caps to a machine shop to shave off a couple thousands from the bottom -at your own risk though

The bearings and races on my D44a that had around 95k on the odometer looked exactly like yours. The aluminum- case D44 was not exactly a brilliant idea by Jeep, since the housing can't take the forces from the live axle -> housing warps and causes bearing failures. It's a good unit for independent suspension rear wheel drives though.. ie. think about Dodge Viper.
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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

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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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Unread 07-22-2013, 12:06 PM   #9
stageninja
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At the machine shop now waiting for guys to come back from lunch. Will post photos after I can get them to proper size.
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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-22-2013, 12:08 PM   #10
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Def looks like driver's side race spun.
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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-22-2013, 12:21 PM   #11
Timo_90xj
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Quote:
Originally Posted by stageninja View Post
Def looks like driver's side race spun.
I wouldn't place my bets on the bearings surviving for too long. You never know though, so it might be worth a shot if you don't pay too much for the shop.
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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,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


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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Unread 07-22-2013, 01:41 PM   #12
stageninja
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Shop fees including tips were 30.00. To pull & press bearings & take 1/2 a thousandth off the base of the drivers side bearing caps. I'll post the photos in the next couple hrs.
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Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-23-2013, 09:47 AM   #13
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After the guys came back from lunch, we removed and pressed the bearing onto the pinion.
new_p_bearing.jpg

Then we discussed the cap with the spun race. Since my guy John IS a rear end expert we settled on only taking 1/2 a 1000th of the base of the caps in an attempt to grab the race with out creating an ellipse from a circle. taking the full 5000ths that was grooved would have been too much. I fully realize this is a gamble at saving this axle that I am so far into. If it works it will be great, if not I will have to get an 8.8 or another d-44 and rebuild that. I am greatly disappointed at what a professional shop did to this axle due to carelessness.
caps_1.jpg

caps_2.jpg

caps_3.jpg

caps_4.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-23-2013, 11:05 AM   #14
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And now reassembly begins. Pinion installed and pre-load @ 15 in. #s rotating torque as per low side of FSM for new bearings. Preload was sloppy w/slight endplay @ only 5in. #s during disassembly.
img_0853.jpg

img_0854.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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Unread 07-23-2013, 11:39 AM   #15
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Diff installed preparing to check pattern w/gear paint.
diff_instld.jpg

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Mine '97 White, ZJ Ltd, 5.2, Up-Country Suspension, Kolak ignition, Kolak/Magnaflow Exhaust
Her's '98 Chargold ZJ Ltd. 4.0 2wd
Our 1st '97 White, ZJ Ltd, 5.2, The parts Jeep for 5 years...R.I.P. Sent to Pic-A-Part 5/17/2013

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