Dana 44 rebuild... Time to set up the gears, advice needed

[Nightstick]

I'm starting on the front axle (D44) and need some instructions to follow. I've seen the blown up diagram of all the parts that go in it, but I'm looking for something that gives me instructions on how to install some new stuff.

I'm putting in a yukon grizzly locker, gears, axles, the whole 9 yards. Me and Izzy did the 9", and there were some specific steps we wouldn't have done had we not had directions. I don't have it all broken down yet (need a few tools), so I haven't opened up the pumpkin yet and looked inside. Maybe it'll be straight forward when I do, so I guess this is just a preemptive post.

Thanks!

 

[RnrdTheFox]

I just did all of this. I would look up Billa Vista's Dana 60 instructions. I know, not a Dana 44, but the same concept for setting up the gears on a Dana 44. It's VERY good. The only other thing I had to look up was the steps for setting up the ball joint preload. I found this on Pirate4x4 also. The rest was rather straight forward bolt up. HTH.

Found the link: http://www.pirate4x4.com/tech/billavista/Gear_Setup/

 

[Nightstick]

WOW! That's a heck of a write-up! Thank you sir!

 

[Skiddy]

I'm starting on the front axle (D44) and need some instructions to follow. I've seen the blown up diagram of all the parts that go in it, but I'm looking for something that gives me instructions on how to install some new stuff.

I'm putting in a yukon grizzly locker, gears, axles, the whole 9 yards. Me and Izzy did the 9", and there were some specific steps we wouldn't have done had we not had directions. I don't have it all broken down yet (need a few tools), so I haven't opened up the pumpkin yet and looked inside. Maybe it'll be straight forward when I do, so I guess this is just a preemptive post.

Thanks!

I don't have one, but i just bought Jason Aldene for that song ok hijack off

 

[NYLES]

put it in measure take it out.....put it in measure take it out........um i got it in 11 try's have fun! you get through the diff and gears the rest is easy!

 

[Skiddy]

put it in measure take it out.....put it in measure take it out........um i got it in 11 try's have fun! you get through the diff and gears the rest is easy!

get your mind out of the gutter:-X

 

[NYLES]

get your mind out of the gutter:-X

skiddy ..........nevermind!

 

[Nightstick]

put it in measure take it out.....put it in measure take it out........um i got it in 11 try's have fun! you get through the diff and gears the rest is easy!

You were askin for it with that one...

It'll prolly take me more than 11 times though

 

[Nightstick]

My initial impression was that I couldn't take the axles and such out without taking the knuckles off. I didn't have a ball joint spanner, and had order one ($56 %)) so I left it as is for a little while. After learning that I could in fact take all that stuff out with the knuckles still on I completed the disassembly today. Tomorrow Im gonna clean and paint, assemble the diff and ring gear, and make the setup bearings.

Reading the article by billavista he says to mark all shims and stuff, since I'm replacing everything anyway is it necessary for me to do that? My guess is no, but feel free to correct me.

 

[Nightstick]

I've read a couple threads dealing with removing the ball joints. Everyone seems to get stuck at the point where the ball joint itself won't come out. Well, I can't even get the damn sleeve off the top joint. I've soaked them in PB, used an impact, and tried a breaker bar to no avail.

Is heating it with a torch the answer?

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[shamu]

bfh and I may have the spanner socket.

 

[Nightstick]

I've got the spanner, won't budge

 

[Nightstick]

Heated with a torch, still won't come out, this is the kinda shit that wears me out! %)

 

[Phil76]

I've got the spanner, won't budge

get a couple of ball joint separators and have somebody hammer one in the bottom while you hammer it in the top.

 

[Nightstick]

I haven't reached the point that I can try and knock em out. For that I have the proper tools... It's the damn sleeve that won't come out to get the upper out.

 

[Phil76]

It's the top one that's holding you up. We wailed on ours with a small sledge hammer until it just dropped out. Then the spanner will work to get the taper sleeve out. A cheap ball joint separator helps also. They're only about $10. Good luck.

 

[enovey]

I just went through the same thing you are going through. Get a good heavy short handle sledge hammer (3lb or anything over the standard 16 oz hammer) and make some solid hits. Thread on the old castle nut to the ball joint before hitting. Make sure it is threaded on so that the castlellations are about even with the top of the ball joint.
With some solid hits the whole knuckle will drop out and then you can press the old ball joints out.
Soak the upper ball joint sleeve that remains in the axle after the knuckle drops out with PB blaster. Using the special tool or a punch and hammer, you should be able to back it out and replace.
Make note of the inserts position (how many full turns until it comes out) as this is important for installing the new one and having it work once back together.
Good luck, be patient.
Hope that helps

 

[Nightstick]

Phil, you are correct! I just read another thread that clarified it for me. Like the other guy I thought the inner portion of the sleeve was threaded around the ball joint so I assumed I had to take the sleeve out first to get the ball joint out. I'll give it another whirl!

If I had just looked at the new sleeve I would have seen it wasn't threaded

 

[NYLES]

somethin dont look right in that pic? never mind good deal all I ever remember was knockin hell outa em until they are beat into submission!!!!

 

[TBS-POPS]

Yeah, broken fingers in the sleeve.....