broken axle shaft need help

[beerthirty]

I broke my driver side axle shaft and when I was taking it out to replace it I noticed that the side with the spilnes had broken off as well now there's three inches of broken axle shaft stuck in the front end. I have a aussie locker in the dana 44, do you guys have any idea's on how to get the broken end of the axle shaft out?

 

[MOLLEY]

maybe a magnet or if u could get a flush grease fitting tip u could force enough grease behide it to push it out good luck

 

[Broncobowsher]

There is a trick using a coat hanger. Form a loop on the end and stick it over the axle. the size and shape need to be so...

It will tightly fit over the axle
Loose enough that you can push it over the axle.
Angled so that when you do get it over the axle you can pull on the wire and pull the axle out.

The idea is that when pushed the hole angles open. When pulled the hole (loop) gets tight and grabs the axle.

 

[beerthirty]

it's just the spines that are broken and stuck. I tryed to just it out from the other side and that didnt work. Im thinking of pulling the cover and pulling off the big gear and the locker but I dont know if that will mess up the gears do you know the answer to that?

 

[blazinchuck]

you can pull the whole carrier out(ring gear/locker). all the shims are on the carrier behind the bearings, so you wont loose them...just make sure that you keep the races seperate for each side-you dont want to swap those on the carrier bearings. Besure to pull/pry out the whole thing evenly, but you may have to pry more on the side without the broken shaft. You dont know how far the broken peices stick out pass the carrier and into the housing tube. Good luck,Chuck

 

[beerthirty]

the shims wont fall off the carrier if I take it out?

 

[blazinchuck]

the D44 shims are behind the bearings. you have to install the shims before those bearings go on the carrier,Chuck

You cant mess anything up, unless you loose the bearing races,swap them,or break'um.Good luck.

 

[beerthirty]

ok I tryed to take out the ring gear and it wont pull out because the broken part of the axle must be binding it up. Any other idea's

 

[blazinchuck]

if you have a magnet, attatch it to something long enough-slide it into the tude and at the same time try to tap the locker with something like a small hammer to jar the shaft loose, maybe even rotate the locker aslo. Truth be known-I'v never had to do any of this, but these are the steps I would do,HTH,Chuck

 

[beerthirty]

I was thinking the same thing I will have to go buy a stront magenet and i will try that I will keep you posted.

 

[blazinchuck]

one more thing...can you knock out the carrier pin/shaft? it runs through the middle of the locker and carrier...I think its a roll rin that holds the carrier shaft in place. If you can remove that, you should be able to knock the broken shaft into the locker and then remove the whole carrier out for repair. Just another thought,Chuck

 

[beerthirty]

my ring gear is to large it wont push out.

 

[bronko69er]

You should be able to get something thin past one side of the cross pin from the passenger's side to push/tap it out. might be kind tricky though. Maybe get a piece of pipe just small enough to fit in the splines and cut all but a little tab off the end to reach along side the cross pin.

 

[bronko69er]

Like this.