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Unread 09-24-2012, 06:32 AM   #1
HaskiE
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First Gear Swap Waggy D44 & Front OX locker

I'm working on changing the gears in a Waggy D44 front axle, 3.31 to 4.88. standard carrier to OX locker. made setup bearings, got the pinion bearing preload, backlash & carrier bearing preload to spec, and finally got a good pattern.

Pressed on the new bearings and had to completely re-do my pinion bearing preload... and then when I dropped in the carrier there was zero carrier preload! and NO backlash! the Timkin bearings are the same part number; setups are The originals from 1991 (I think) and according to the surface plate at work they're about 0.0045" shorter than the new ones... what would cause this?? I measured the bearings 3 times just to be sure, the old ones are smaller...



ruined shims... going to order more...



Did I press on the new bearings ...too hard? I'm starting to think the shims walked up the taper on the ox locker? Has anyone put interior shims on an ox-locker?

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Unread 09-24-2012, 02:01 PM   #2
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anyone?
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Unread 09-25-2012, 01:15 PM   #3
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just happens sometimes.
i've had one out of 5 axles do that when the real bearings went in.
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Unread 09-25-2012, 01:27 PM   #4
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Quote:
Originally Posted by ratmonkey
just happens sometimes.
i've had one out of 5 axles do that when the real bearings went in.
Weird. Thanks ratmonkey! I was starting to think I really F'd something up. What'd you do to finish the axle? Should I make another set of setup bearings?
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Durango Steeringbox, No track or sway bars, CJ tailgate, on 31's :)
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Unread 09-25-2012, 03:06 PM   #5
ratmonkey
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Quote:
Originally Posted by HaskiE View Post
Weird. Thanks ratmonkey! I was starting to think I really F'd something up. What'd you do to finish the axle? Should I make another set of setup bearings?
compared measurements and made an educated guess. had to adjust while using the really real bearings twice. it sucked, but sometimes those are the breaks. a clamshell style puller would have made things easier. went through an extra pack of shims cause i couldn't be careful enough.
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Unread 09-25-2012, 05:49 PM   #6
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How did th pinion preload change? Doesnt the front pinion use shims and not a crush sleve? If so your pinion preload should not have changed.
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Unread 09-25-2012, 09:31 PM   #7
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Quote:
Originally Posted by HARLEYX2
How did th pinion preload change? Doesnt the front pinion use shims and not a crush sleve? If so your pinion preload should not have changed.
No crush sleeve, yeah, shims on both ends. I made setup races (now I know I only really needed one setup race!) And I'm guessing the bearings are slightly a different size because after I drove in the new races (with what I thought were the right shims behind the big race), and was bringing the pinion to torque I could feel the preload get waaaay too tight... tested to well over 40in lbs; spec is 20-25; so I re-did the preload hoping nothing else changed; but that's when the carrier just slid in with no preload or case spreading... :/
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Unread 09-27-2012, 09:00 AM   #8
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The bearings are different due to variability and being used. Its why you need shims and why there are different preload numbers for new vs used bearings.
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Unread 09-27-2012, 09:58 AM   #9
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Quote:
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The bearings are different due to variability and being used. Its why you need shims and why there are different preload numbers for new vs used bearings.
Just ordered another set of bearings & shims (exact same kit) going to shelve my old bearings and make the new ones I have already into setups. hopefully I can get this on try #2!
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Unread 09-30-2012, 12:37 PM   #10
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Good luck with try #2. It usually takes me 10 to 20 tries to get a dana setup correctly.
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Unread 10-01-2012, 01:01 PM   #11
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Good luck with try #2. It usually takes me 10 to 20 tries to get a dana setup correctly.
hahaha I hear that! It took me about a whole afternoon to get the shims right on the pinion first and then the carrier took about the same, and then I did the pinion again... I dont even want to think about how much time I have into this!!!! but, learning takes time. Next I'm honing the bearings out with the dremmel to make the new setup's; when the new bearings finally get here with the new shims hopefully I't be a swap and load, done....
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Unread 10-17-2012, 06:05 PM   #12
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Ok so new bearings finally came in, and I'm making my new setup bearings, and maybe I'm over thinking this, but I wanted to get your guys thoughts on this; Last time I swapped out all 4 bearings (cone+race) for setups. I'm thinking it might be smarter; or (possibly the right way?) to start with the final side races & final inner cone? Ie, use as many final parts as I can...? Drawing:
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Unread 10-17-2012, 08:10 PM   #13
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on the d44/60 i use the "good" inner pinion cone and outer pinion cup. they don't have anything under them that needs adjusted so there's no reason to go through the effort of set up bearings/races.
i use whatever was matched up on the carrier bearings.
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Unread 10-18-2012, 05:25 AM   #14
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Quote:
Originally Posted by ratmonkey View Post
on the d44/60 i use the "good" inner pinion cone and outer pinion cup. they don't have anything under them that needs adjusted so there's no reason to go through the effort of set up bearings/races.
i use whatever was matched up on the carrier bearings.
That's just what I wanted to hear! thanks man!

I made 2x setups last night, hopefully I can make some progress tonight.
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2.5" TJ exhaust, WJ valve cover, XJ Computer, External Slave Cyl AX15,
Durango Steeringbox, No track or sway bars, CJ tailgate, on 31's :)
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