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Unread 11-20-2013, 01:53 AM   #1
Tradesman300
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Super D44 Difficulties

First the background: This Spring I installed new outer (shaft) bearings and seals, as well as inspected the limited slip carrier for excessive signs of wear, excessive backlash etc. Everything checked out. I reassembled everything and filled 'er up with fresh fluids.

Fast forward to July, add 500 miles and we arrive on the trail.

Boom.

Spider Gear Grenade Goes Off.

The Spider gears both blew to pieces while on a hill climb. One of the pieces cracked open the stock diff cover like a can opener as the ring gear finished off the pieces and ground them down to fragments.

Trail run over.

That brings me to today. After much research, discussion and agonizing I decided on the following direction for my d44 rear:

Replace Stock 3.72 gears with G2 4.89 gears
Replace Stock carrier with Eaton's Detroit 33 Spline 'Super 44" locker
Replace Stock Shafts with G2 Alloy 33 Spline Shafts
Replace all bearings etc. (obviously)
Move carrier shims outboard of the carrier races instead of on the bearing journals (Eaton, Randy's, watercooler all agree)

Now as I am attempting to do the setup I come across the following problem - I cannot get enough side-to-side adjustment to correctly set the backlash.

Eaton says the carrier is 1/4" narrower because they make only one variant instead of a 3.92 up and a 3.92 down. This way they can accommodate all gear sets. MY issue with this statement is that I only have .136 of shims in place and that is WITH the recommended case spread of .015 applied via Case Spreader Tool.

When I install all .136 of these shims on the left side of the carrier and .000 (none) to the left side I still have .028 of backlash. The recommended range is .006 - .0012.

It would take .030 of adjustment further into the pinion to achieve a .007 setting ( Yukon estimates .010 of shims shifted from right to left moves the backlash .007 downward).

So I am stuck with a dilemma here. What to do?

The option that seems both the most logical and the most crazy at the same time is to machine down the inner surface of the housing where the bearing cup/shim makes contact. This would be a tricky business as I am not a machinist nor do I have a professional machinists tools. What I do have is a very good air sander and a lot of 400, 1000, and 1500 grit discs for said sander. I think I can be very very patient while carefully removing .035 or so of the surface to give me my theoretical additional adjustment that is needed.

Thoughts?

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Unread 11-20-2013, 08:23 PM   #2
Tradesman300
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bump. Needing help still.
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Unread 11-20-2013, 08:45 PM   #3
lar308
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Hey, I'm a ASE master tech. I believe I understand what you're trying to do. What series carrier do they sell? Was the ring gear a thick gear or a normal gear? Does the ring gear thickness match the carrier you have? If the carrier is a 3.73 and down design, you will need a thick ring gear. I also believe you would reach the tollerences needed by trying to machine the case by hand, you'd also weaken the case. Let me know if I can help. Ron
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Unread 11-21-2013, 07:59 AM   #4
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If I am reading your post right ( and that's a big if ) can you machine down your carrier to make room for the oversize in your set up.
Two spot that can be machined down and should not have any affect on the overall strength is the bearing journals or the face where the ring sits.

Or try contacting http://www.pirate4x4.com/forum/axles...l-housing.html

This guy knows his axles and will be happy to help.

Jason.
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Unread 11-21-2013, 10:18 PM   #5
Tradesman300
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Thanks Jason. I have a post out on pirate too. I'll give him a holler.
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Unread 11-25-2013, 11:30 PM   #6
XJ Jay
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providing your pinion depth is close and not too shallow, it sounds like you need thick cut gears, what i find is odd is the fact only need .136 total shim stack for back lash, i just did a tj 44 with 33spline detroit locker and 4.10s and i recall needed .250 ish worth of shims for back lash. Also needed to use a thinner bearing with a larger ID for make room for those 3 extra splines. ill try to remember and look at my install kit where i write down pinion depth and back lash shims i used durring set up and see how much backlash shims i used. maybe post a pic of your dif with the carrier and gears installed
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Unread 12-03-2013, 10:18 AM   #7
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To use a 4.88 ring on a Dana 44 Series 3 carrier you have to use a thick ring. Note that Jeep TJ Rubicon Dana 44 rings are all thick. The TJ Rubicon D44 rings use 7/16" ring bolts as I recall. So you may have to drill out the ring bolt holes on the carrier but otherwise it will fit. Note that a JK Dana 44 gear set is a different animal and won't fit. You probably have a standard thickness gear set in 4.88 that won't work with a series 3 carrier.
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Unread 12-06-2013, 01:04 PM   #8
Tradesman300
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Quote:
Originally Posted by foggybottombob View Post
To use a 4.88 ring on a Dana 44 Series 3 carrier you have to use a thick ring. Note that Jeep TJ Rubicon Dana 44 rings are all thick. The TJ Rubicon D44 rings use 7/16" ring bolts as I recall. So you may have to drill out the ring bolt holes on the carrier but otherwise it will fit. Note that a JK Dana 44 gear set is a different animal and won't fit. You probably have a standard thickness gear set in 4.88 that won't work with a series 3 carrier.
This is a Detroit D44 Universal Fit carrier. The Eaton notes I got said that specifically, you are NOT to use the thick ring gear set.
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