This weekend I will begin the process of swapping out my new dana 44 out of a scout. I will be shortening to WT width and using my dana 30 outers. I have done alot of research and have a complete grasp on removing C's, cutting axle, setting pinion angle, caster angle, and relocating/grinding down perches. My first task is to remove the outer nuckles/remove shafts/ring and pinion for a tedious inspection and cleaning. The only thing i am struggling on is getting started rremoving the scout outers. i have seen a few brief write ups and/or pictorials otherwise I will be shooting from the hip. Any help or guidance from those that have done this swap would be great.
grind the weld off very slowly.You say you are cutting one side to CJ7 WT
I cut 3 5/8's off one side. if you cut that side first just grind off weld and then just cut the tube left inside a few times and knock out. Throw the other side on a grill or in the fire and knock it off too.
does it have 6 bolt hubs keep those. remove those and remove the nuts
pull out the bearings slide off the disc put one nut back on and hit with hammer this will start to move the spindle off. don't wreck the treads.
now you can pull out the axle shafts.
Remove lockout hubs which gives you access to the spindle nuts. Remove those and the wheelbearing hub comes off, giving you access to the spindles. Remove the spindles and the axleshafts can come out. Once the axleshafts are out you can remove the nuts from the balljoints and knock the knuckles off of the inner C's.
That's it in a nutshell. Get yourself a CJ service manual. There's a sticky thread in this forum with one that's downloadable. The Scout outers are almost the same as CJ, so the disassembly is pretty much the same as breaking down a CJ Dana 30.
Last week i began the teardown. Pulling the hubs was actually easier than i expected. About 45 min for each side. I purchased a 2 3/32" hub socket for like 25 dollars from orileys. When i got down to the nuts they already had notches from where someone had used a screw driver. for those that are not reusing any parts from the outers i would just use a screw driver to remove these nuts and save your money on the socket. The hardest part was pulling off the caliper. Ended up heating up and beating out the shim holding it in place. Not sure if there was an easier way?? I made sure to keep ring and pinion / shims for reference when I install gears.
Tonight i began grinding to remove the C's. I used a wheel grinder with a 1/8" wheel. Tried to beat each side off but didnt have a large enough hammer. I grinded down the weld as close as i could without getting into the tube. I do have a few concerns that i realized tonight. Please way in with your input. It appears that some water had sat inside the housing. You can see rust that formed at the top of the bearing race caps. there is also slight rust on the edge of one of the races. Do you guys think this is ok? should i do anything about it?