Removing broken D44 axle from behind the inner seal - any suggestions???

[Buldozer]

I assume you can't remove the pin with the ring gear attached?

You're not going to have much room around the pin. Figure the diameter of the axle splines minus the diameter of the pin, then divide that in half.

Correct on not being able to remove the pin...I guess I will try driving something in there around it if possible. Sure will have to be thin.

 

[Buldozer]

Ok, problem solved. Got the stub out today with a tool I made special for this purpose. I welded a Wal-Mart metal tent stake (like a big nail) on the end of a piece of 1/2" black pipe. The stake was about 5/16" in diameter but that was too thick to get passed the pin in the diff, so I ground two flat sides on it. It would not pass until I got it to approximately 3/16" across the flats, then that broken stub just slid out easy as you please. I will post some pics for the next guy that searches for a fix on here. Oh still not back together because one side was missing the spindle bearing seal....so back together as soon as I find one of those.

 

[rmfreeze]

Necessity is the mother of invention! Good job Rick.

 

[Buldozer]

Thanks, finished it all up today...was missing a couple of spindle seals . The local Advanced Auto Parts was able to order them in for me, and I got them after lunch today. Good service for those guys to get them in on Sunday morning...packed all the bearings, installed new axle seals as well and put everything back together and tried it out this afternoon. It ran good. I need to check for binding at full lock but I am sure it will be ok. The new axles are a lot stronger looking. I put in CTM joints and they look tough as well. Now just need to take a run over to the park and try them out! We are off for a few days of well deserved vacation so this next weekend is out, but after that, we need to make another run....are we still looking at a run on 7-25-09? ;D