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Gonna lock the dana 44 and need help

That sounds like my experience this weekend.
I pulled the shafts out to make sure my spare shafts would work for that axle(mid-70's flat top 44 w/4.10).
I did the drivers side first,then pass.side.
Pass. side spare was to long so I put the original back in and spun the rotors and thats the sound I got(same as you're describing)from the drivers side.

I tore it down to find out that the d-side shaft was to short and wasn't engaging the spider gears(or whatever)

So maybe the PO just threw it together with what he had(being shafts too short)and called it good.

HOWEVER,did you check these out at all before you handed over your cash?
 
I would do a complete rebuild on it considering that there is rust in there. Appears to have sat with some H2O in it.
 
Fron one of the pIcs it looks like there is no axle stub in the side gears. It may just be the way the pic was taken. Jam a screw driver in the carrier and try to spin each sides rotors and have some one look in there while you do that. I am betting its a broke axle shaft. It can catch every now and again and make that sound.
 
carpeonnel said:
It's not the lockouts cuz you can see the axle joint not moving in the knuckle when it's chattering and moving when it stops chattering.
Click to expand...

This would be consistant with a slipping lockout.
 
Tore it apart and the Driver side axle is messed up. It appears that splines are worn down. I pulled the carrier as well and the pass. side axle fits tight in both side spider gears and the splines look good in the side spider gears but the drivers side axle is either too small or just worn down. You can place it in the side spider gear, since the carrier is out, and you can feel a lot of play and can make the axle slip by grabbing the spider gear and holding it while turning the axle. So, on the good side all I have to do is replace an axle, but I found more problems. Stud broke off in the pass. knuckle and the bolt that holds the crosspin in has been broke off so it's jammed against the cross pin and I can't remove the cross pin.
 
"Stud broke off in the pass. knuckle and the bolt that holds the crosspin in has been broke off so it's jammed against the cross pin"

Not sure what stud you are referring to on the pass knuckle. You talking the 6 studs that hold the spindle on?

The lil bolt that holds the crosspin in the carrier usually isn't on there super tight. Is there a way you can slot the end with a small cut off wheel or dremel enough to get a screwdriver in it? If not- do you have a welder?- Take a nut and set it on the broke stud and fill it with weld. I know thats tricky cuz it's so small. JB weld may do the trick too. Then again there's always an easy out.
 
Yeah, I'm talking about the passenger side knuckle that has the 6 studs that hold the spindle on. One of those is broke off.

I'm gonna see if I can find an easy out, but that bolt is so small it makes things difficult. Evidently the person before me must over tightened it and broke it off half way cuz it's way down in there
 
Would it be possible to simply drill the dern thing out and retap it for the next larger size? OR if it's broke way in there and you have like 5-6 fine threads exposed maybe you can just get a new bolt and grind to length and use it- just leave the old part inside.

The stud on the knuckle has to be a pressed in thing. I've never changed on. Can prolly rob one from your old axle. Clean the back of the knuckle off and make sure it looks like it can be either pressed or beat out.
 
I hate to rob one off my 10 bolt mainly cuz I don't want to go through tearing it down. But, I was just wondering if anybody happened to have that part number cuz I can just see the confused face on the auto parts store clerk's face now when I tell him what I need. The old one came out easy. Whacked it with my dead blow and it popped out.

Well, I would just leave the damn thing broke off against the cross pin, but I'd rather go ahead and try to fix it before I wheel it and something bad happen
 
I hear ya. I'd try and do the same. My guess is that stud is a dealer item. Be prepared to pay prolly $7 for one. Let us know.
 
Check this out. I figured it all out. The dumb bastard I bought the axle from evidently thought you could interchange a 10 bolt axle (27 spline) with a Dana 44 axle (30 spline). I went outside and counted the splines on the axle I pulled and of course it's 27 spline. I guess that explains why it was clicking, clacking, and sometimes grabbing. Live and learn
 
10 bolts came with either 28 or 30 spline depending on the year of axle.

There were no such thing as 27 splines on GM shafts.
 
If you broke one of those 6 little studs that hold the spindle on, they are just pressed into place. Get yourself a punch and a hammer and pound it out unless you have access to a press and use the press to press it out :thumb:
 
Sounds like you are well on your way to solving al your probs. Sell or trade your axle shaft for the one you need.
 
Hey I'm dredging this back up to see if any of you guys know where I could get another bolt to hold the cross pin in to the carrier. I bought a lock right for the front and then I remember that I had that bolt broke off against the center pin. I have a couple left handed drill bits and somehow we'll get it out to put the locker in, but didn't know if one of you guys had a bolt of knew one I could grab as a replacement
 
You can try a junkyard, or I think Dorman might have a listing for one.
 
yeah check your local part store for the bolt that holds the cross pin in. It will be in the help section, or dorman. I know OReillys keeps em in stock.
 
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