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Broke a D44 inner- Can't get the spline part out.

Discussion in 'The Garage' started by FWP, Jun 3, 2002.

  1. FWP

    FWP CRS

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    Broke a D44 inner- Can\'t get the spline part out.

    Twisted the short shaft inner clean off. I can't get the inner stub, with the splines, past the seal. Anybody have any tricks? I tried prying it out thru the lube channel with a screwdriver and a magnet on the shaft end- no go. I really don't want to take the carrier out (Powertrax locker in there- pain in the butt to remove), but I will if I have to. TIA
     
  2. Esteban86K5

    Esteban86K5 1/2 ton status

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    We had to take out the carrier on a 12 bolt out in the field for the very same thing. Basically the splines had mushroomed and had to be pounded out. Good luck.
     
  3. Mudzer

    Mudzer 1/2 ton status Author

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Sounds like you need a more powerful magnet. Try buying a steel dowel rod and buying a good sized magnet. Weld a small round plate to the end of the dowl roughly 1/8" diameter bigger than the magnet. Glue the magnet using a good industrial adhesive. The extra size of the plate will get you past the seal without damaging it. Weld a similar "scoop" on the other end to clean out the mud and dirt. Unless your splines are screwed up, you should not have a problem getting this out of the carrier and out of the tube.
     
  4. Grim-Reaper

    Grim-Reaper 3/4 ton status Author

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    One of the neatest tricks I have heard of is one A guy in my club did. Had the same problem with a chunk stuck in the diff. He took a few welding rods and welded them end to end till he could reach the chunk. Looking through the tube he lined the end of the rod to the center of the broken peice. Clamped the stinger on for a second and welded the rods to the broken chunk and was able to yank it back out. /forums/images/icons/smile.gif
     
  5. Mudzer

    Mudzer 1/2 ton status Author

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Be careful not to weld your broken axle into the diff!! /forums/images/icons/crazy.gif
     
  6. FWP

    FWP CRS

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Thanks Neil, Eric, and Esteban- I got some good ideas from all of you /forums/images/icons/smile.gif

    Here’s what I came up with:

    Supplies needed-

    Long piece of 3/8 all-thread with a nut on the end
    JB Quick epoxy
    Brake clean
    Paper towels
    Long grabber tool
    1 friend
    2 adult beverages /forums/images/icons/smile.gif

    Procedure:

    1. Put wad of paper towel on end of grabber, and apply brake clean.
    2. Clean end of broken axle shaft piece.
    3. Mix up JB weld and apply to end of all-thread with nut attached (for surface area).
    4. Stick all-thread into axle tube, to let JB weld cure.
    5. Consume adult beverages, discussing various aspects of life with friend (wife, in my case) waiting for JB weld to cure /forums/images/icons/laugh.gif.
    6. Remove broken axle piece by pulling on all-thread.
     
  7. Don

    Don 1/2 ton status

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Why not take the other Axle out, stick a piece of 1/2 pipe, or whatever through the entire Axle assy, and Knock out the broken Piece?
    Yes it"s more work, but less then Pulling the Carrier.
     
  8. HarryH3

    HarryH3 1 ton status Author

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Be careful using the JB Weld in there. That stuff is very liquid until it's set up for about 5 minutes. You don't want it running down into the splines or bearings. /forums/images/icons/shocked.gif
     
  9. FWP

    FWP CRS

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Thanks. I thought about that, but the cross-shaft would be in the way. I couldn't get the cross shaft out without removing the ring gear from the carrier. I wasn't able to pull the carrier either, because the broken stub was too long to clear the housing. I had to improvise.
     
  10. FWP

    FWP CRS

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    Re: Broke a D44 inner- Can\'t get the spline part out.

    Harry, you're right. I waited a few minutes before I applied it to the all-thread, so that wouldn't happen. Good advice for anybody that tries my method/forums/images/icons/wink.gif
     

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