Dana 44 axle tube seperating from diff housing - JeepForum.com
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Unread 08-05-2010, 06:22 AM   #1
Jeeeps
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Dana 44 axle tube seperating from diff housing

I did a search with no luck...

Has anyone had this problem of the axle tube on the rear dana44 seperating from the diff housing and causing a small oil leak at that location? Is my mate's TJ up for a completely new axle housing or is the axle tube able to be re-welded/fixed to the diff housing? Are there any repairs out there before his mechanic orders a completely new rear end? We've been told by a few people that it'll need to be thrown away because welding is not an option.

cheers

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Unread 08-05-2010, 06:26 AM   #2
j_niko
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Re-weld

Make sure you have the correct depth in the housing first
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Unread 08-05-2010, 09:39 PM   #3
Jeeeps
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Originally Posted by j_niko View Post
Re-weld

Make sure you have the correct depth in the housing first
Thanks, although everyone i've spoken to seems to think that's not an option. I'll have to hunt out someone who specialises in jeeps i think.

cheers
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Unread 08-05-2010, 09:45 PM   #4
ratmonkey
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Something bad happened to make that happen. I would not reweld that tube. If I were particularly attached to that diff I would have it totally retubed. Otherwise get a new axle.
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Unread 08-05-2010, 10:08 PM   #5
Jeeeps
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Originally Posted by ratmonkey View Post
Something bad happened to make that happen. I would not reweld that tube. If I were particularly attached to that diff I would have it totally retubed. Otherwise get a new axle.
The crazy thing is that the jeep hasn't done much more than beach work since it left the factroy.

cheers
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Unread 08-05-2010, 10:32 PM   #6
jdhallissey
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Can you post pics of it separating. I really think that you can't hurt that rear end that bad by only beach work. I mean you would have to just get plain stupid to do that. Also to add to that fact, I have seen tubes twist but never pull out.
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Unread 08-06-2010, 12:28 AM   #7
mrblaine
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Originally Posted by Jeeeps View Post
Thanks, although everyone i've spoken to seems to think that's not an option. I'll have to hunt out someone who specialises in jeeps i think.

cheers
Horsepuckey! Drain the diff and clean it out well, if you use brake cleaner, make sure it's all evaporated before you start welding. Use the brake backing plates as a guide to line the tube back up with the other one and smack it back in place with a sledge and block of wood, rotate as needed.

Spray down the end of the tube with a solvent and compressed air to get it as clean as possible and then remove all the paint as far into the crack where the tube meets the casting as possible. Also do the same where the original plug welds that held the tube in are.

Take a cutting torch and use it to clean out the crack as well. If you hit the Oxygen cut lever before the metal is hot enough to oxidize and cut, it will just clean out the paint from deep in the crevice.

Once you get it shiny clean, no paint, no oil, no dirt and the tube lined back up, run a Mig pass around the tube to the diff and then re-burn in the plug welds. If you wish, you can use the torch to warm up the weld area slightly to drive out moisture from the cast diff section.

If you do it this way, it will be fine.

Back inside the diff, run a bead of silicone and wipe it around the juncture where the tube ends inside the diff. That will stop oil from weeping out the tube.

At the end of the day, we're talking a couple of hours to save a diff housing. Even if it fails to stop the leak, that's all you've lost.
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Unread 08-06-2010, 03:16 AM   #8
Jeeeps
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Thanks for the comments guys. I went over and took a look and it doesn't really look any different to my tj's d44. We degreased it and cleaned it right up and took it for a long drive (30 miles) to get the diff nice and warm. After the nice long run there were no leaks, cracks or damage that i could see. The leak might be coming from elsewhere, but with nothing leaking at this stage we'll just have to keep an eye on it. We might flex it up a bit on the weekend to see if that's what it needs to leak.

cheers
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Unread 08-06-2010, 09:03 AM   #9
newracer
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mrblaine is correct. I had my front done before it was trussed. Pretty common and easy fix.
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d44 , dana 44 , axle , seperating , housing , driveshaft , tj , wrangler

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