The new (old) dana 44 *56k warning, pics*

[the Captain]

Re-check the part numbers, check the runout. Where were the ring gear and carrier at before they were brought together, if the gear was inside and the carrier was outside in the cold that could be why it went on so easily.

[rstarch345]

This is going into a 3 year axle project. How are you remembering where you left off?

[herman8r2]

This is going into a 3 year axle project. How are you remembering where you left off?

HAHAHA!! It's easy to remember where you left off if you never have time to start... And besides, all I have to do is look back over this thread and I'm right back where I was

[herman8r2]

Cleaning and repairing the axle housing...



The OX locker mated to the new 4.88 ring gear...



The homemade Housing spreader... As cool as it gets



The G2 shim package was lacking any shims under .009, and does not have enough outer pinion shims, but 4WD is going to see what can be done about that...



So to follow up on the loose ring gear, I checked the runout on the carrier and on the ring gear and am a bit more worried than I was. That was a good suggestion from the Captain about a possible temperature difference, but no cigar, both parts were on the same bench in the same shop. Checking carrier runout... .002 inch



Checking ring gear runout... .006 inch. Seems a bit too much to me, but this is my first axle build, anyone know if this is in spec?



Initial coast side contact pattern...



Initial drive side contact pattern...




So, how about some input?

(edit)Wow, I need to shrink those pics some more

[herman8r2]

OK, I think I am back on track. After talking to Brian Stewart at 4WD, I got a spicer shim kit with all the shims I needed, thank you Brian. After talking to the guys at OX locker and G2 gears, I determined that I was unlucky enough as to receive a locker assembly and ring gear on opposite ends of tolerance. As neither one was out of spec far enough to replace, the guys at OX gave me a couple of suggestions on how to fix the fitment/runout issues. I was advised to 'clock' the locker pieces in the hope of finding a better alignment. I was able to cut the carrier runout in half (down to .001) by rotating both caps counter-clockwise two bolt holes on the carrier unit. In order to get the ring gear to fit tighter on the locker, they advised me to peen the ring gear mating surface of the locker unit. I took it one step farther and marked the low side of the mating surface, and peened that side, sucking the ring gear as far as I could to the low side. After I got the ring gear to fit without any play, I also 'clocked' the ring gear by marking the high and low side of the gear and aligning the low mark on the gear with the high mark on the locker. I repeated that three times and was able to cut total runout on the ring gear down to under .003. I'll get some more pics up in a few days...

[Blupupher]

wow, that is some tinkering to get it set.

[herman8r2]

wow, that is some tinkering to get it set.

Tell me about it... At least I got pretty lucky with the rest of the setup. I didn't have to mess with pinion depth or the carrier shims once I pressed the permanent bearings on Although it did take a couple of hours to get the pinion bearing preload right... Even if it does feel too tight, the torque wrench doesn't lie... unless it's out of calibration. But I'm not going to think about that.

[LeadFoot]

Dude I remember when you started this thread...props for not calling quits! Dang!

[herman8r2]

Yeah, it's been on the bench for a LONG time. It sure does feel good to be making a bit of forward progress again... I guess if it was the only vehicle I had, I would have had to get it done a while ago. The gears are set up, I'm just waiting for some brake parts and axle bearings now, oh, and a driveline. I'm kinda excited to drive it with the lower gears, I'll be able to smoke the tires and break stuff again...

[herman8r2]

So I called 4WD yesterday to see where the parts I had ordered two and a half weeks ago were... It seems that they are supposed to ship out today or tomorrow. I am somewhat disappointed in our host for the lack of communication regarding orders that are going to be late. I was expecting parts to show up a week ago at the latest, only to find out they haven't even shipped yet. It would go a long way toward easing the frustration of waiting for parts if I got an email or a phone call saying "hey there Valued Customer, we appreciate your business, and are sorry for any inconvenience this may cause, but part number so-and-so is on back order and isn't expected to be in until xx/xx/2012..." I'm sure that there is a good reason for the parts to be late, I just don't like being left out of the loop, especially after spending over $4000.00 with our host in the last few years. Ok, while I don't really feel better, I'm done.