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Unread 11-25-2013, 09:30 AM   #1
moore14
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Spider gear replacement

Good morning all-
2006 LJ 6' lift Dana 44 35' dick cepek crushers..

I am needing to replace my spider gears and I have never tackled anything like this. I searched on here and found no real write ups or anything on how to do this. If anyone can help I would really appreciate it. I do not want to take it to the shop and pay $250 to do something I know I can do with all of your fine help....

Thanks!

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Unread 11-25-2013, 01:03 PM   #2
Eckoh
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What did you do to wreck your current spiders??
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Unread 11-25-2013, 01:54 PM   #3
moore14
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Honestly no Idea. I have had a popping sound for a while when I turn at slow speeds. Popped the cover off and the teeth are pitted
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Unread 11-25-2013, 02:53 PM   #4
Brimstone
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Should be fairly simple. I haven't done a D44 but I did replace the ones in my old D35. There are some differences but the procedure is similar. For the D44 it is more work to get the axle shafts out.

Please note that this will work only if you have an open differential. If you have a LSD there are clutch packs behind the side gears, and as far as I understand it requires more work and special tools to disassemble, and may require removal of the whole carrier. If it is an open differential you should be able to replace them with the carrier in the axle, using something along the lines of the following procedure:

-Chock the front wheels, lift the back end, secure it on jackstands. Do not just put it in Park or gear and engage the 4x4 to secure the front wheels. You will need to put the transmission or transfer case in neutral so you can rotate the differential carrier.
-Crack open the differential cover to let the fluid start draining.
-Remove the wheels and all brake components so you have access to the axle hubs.
-Using the access hole in the hub, remove the four nuts securing the axle retaining plate.
-Remove the axle shafts; you do not have to pull them all the way, just far enough to get the axles clear of the gears inside the carrier.
-Inside the differential, on the side of the carrier, there should be a hex bolt securing the cross shaft. Remove the bolt, then slide the shaft out.
-Rotate the side gears until both spider gears and washers are free.
-Remove the side gears and washers.

Installation is opposite of removal. It may take some trial and error to get the gears all back together properly. Also, because the axles were pulled you may have damaged the outer axle seals. Some people recommend putting RTV around the seals, I can't comment on that method as I haven't done it myself. Also, Jeep instructs to use new axle retaining bolts and nuts after removal instead of reinstalling the old ones. Those can be hard to source. At the very least I would recommend putting loctite on them if you reuse the old hardware.

If someone who has more experience with the D44 could clear up, you might be able to get the gears out without pulling the axle shafts (which would eliminate like half the work required). However, I don't think there is enough room inside the carrier to get the side gears out without pulling the shafts back at least a little bit. Again, if someone with more insight on this could comment that would be great.
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Unread 11-25-2013, 03:16 PM   #5
otisdog
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Depending on what gears you have you might have to pull the carrier and remove the ring gear to get the cross pin out. Also - there probably is a roll pin securimg the cross shaft and not a bolt. It has to be driven out with a punch

http://www.jeepforum.com/forum/f19/d...teeth-1795601/

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Unread 11-25-2013, 03:51 PM   #6
Gabe
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Had to pay a gear specialist $85 to put together my D35 Trac-lok spider gears. I took out the carrier though. Is yours open or does it have an LSD?
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Unread 11-25-2013, 04:56 PM   #7
apaTJ
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I recently replaced an axleshaft and accidentally dropped the spider gears out. I had a D35 limited slip so I'm not sure how yours differs. But I had a had a helm of a time getting the thrust washers to stay in place while putting the spider gears back in. Just have patience. I think it's easier without a LS because there's less pressure on the spiders. The method I used was just put the side ones in and then rotate the top and bottom ones in with the washers like half way to where they are supposed to be wedged in with the gear. It was kinda just trial and error. Oh and hint make sure you space the top and bottom gears right. If you get one in place an the others wrong you have to start over
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Unread 11-25-2013, 05:18 PM   #8
Brimstone
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Quote:
Originally Posted by otisdog View Post
Depending on what gears you have you might have to pull the carrier and remove the ring gear to get the cross pin out. Also - there probably is a roll pin securimg the cross shaft and not a bolt. It has to be driven out with a punch

http://www.jeepforum.com/forum/f19/d...teeth-1795601/

Jim
I believe you may be right. My 2000 FSM shows that the Dana 44 has a hex bolt, but I checked the '05 FSM and it says there is a roll pin. I wonder if there is a reason for the change?
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Unread 11-25-2013, 07:15 PM   #9
CharlieHo
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Quote:
Originally Posted by Brimstone View Post
I wonder if there is a reason for the change?
Ran out of bolts, duh.

My 06 has a pin also. And you have to pull the carrier as the ring gear is definitely in the way of the cross shaft.

Stock 3.73 gears with open carrier(for now)
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Unread 11-26-2013, 05:58 AM   #10
moore14
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I have a LSD
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Unread 11-26-2013, 11:30 AM   #11
Brimstone
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In that case I would recommend getting a shop to do at least part of the work. As someone above mentioned you could break it all down and pull the carrier out yourself, and take the carrier in to a qualified shop to have the gears installed.

How many miles are on your TJ? You may want to have a new set of clutch packs installed in the LSD at the same time. Once the side gears are out the clutches will be free and can be replaced with no extra work. Depending on how many miles are on it, and considering the damage that was done to the spider gears, the clutches could be worn out. Once the clutches wear out it will begin behaving like a regular open differential and you will have lost all the benefits of the LSD.
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Unread 11-26-2013, 01:38 PM   #12
moore14
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Good point... yea it just hit 103K. Man I hate having someone else do it.
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