Rear Pinion Seal Change Made Easy - Dana 44a
First let me say two days for this job was TOOOO long. The job isn't that hard but having the right tools available is essential. Here is a short write up that hopefully saves someone time in the future.
2: Wire Brush
3: 8mm socket
5: Flat Head Screw Driver
6: Paint Pen
7: 34mm Socket
8: Impact Wrench
9: Seal Puller
1: Clean around the Pinion Seal (degreaser, sire brush)
2: Undo the 4 U-Joint bolts with the 8mm.
3: Hang the drive shaft to the side (this insures the shaft will align correctly during reassembly).
4: Clean all debris from around the nut and yoke saddle (wire brush, screw driver).
5: Mark Nut and Yoke position (Paint Pen - See picture below for example).
6: Remove the Pinion nut (34mm socket).
7: Separate the Yoke (flat head screwdriver will pry it out easily).
8: Remove Pinion Seal (seal remover).
1: 34mm socket is available at auto parts stores - not tool stores.
2: Removing pinion nut is easier with a 1000 ft lb impact wrench. My 250 ft lb, useless, 400 ft lb, useless, 1000 ft lb, wrench successful.
3: After buying the new impact wrench (air tools) I learned plumbing for a 3/8" connector is different than the typical 1/4" connector. This took time to sort this out.
4: A seal removal tool is the fastest way to remove a seal. Skip the screwdriver and all those other things. Just go all in with a $10 tool.
If I had this to do again it would take me less than 1 hour.
1999 WJ 4x4, 1997 ZJ 4x4
1997 Mountaineer 4x4, 1996 Explorer 4x4
1972 Mustang Mach 1 351 Cleveland, 1972 Mustang Coupe 302
1970 Chevy C-20 350, 2002 Kawasaki Vulcan