Checking splines on a Dana 44?
- Thread starter JMT
- Start date
Pull the axles. Its the only way. Not too bad on a 44. Remove the brake caliper, then the disc. At that point, you will see the axle flange. It has a hole through it to put a 9/16 (IIRC) socket through. There are 4 nuts holding the axle retainer to the housing. pull those 4 nuts off, and the axles will slide out. I think you can do all that without pulling the parking brake assembly. Note, pulling the axle will allow the diff fluid to leak out, so make sure you have a catch pan.
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To avoid fluid loss just Tilt the axle up on the side you are pulling. Do em one at a time and you won't have a mess.
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There must have been a time
when we could have said no.
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There must have been a time
when we could have said no.
Thanks for the clarification Jerry. I couldn't remember if they needed a 1/2" or 9/16" socket.
Thanks, I got confused because of a video I watched where they were doing a front. And I’m assuming the brake caliper removal is also a 1/2”. I’m bringing some other tools just in case. And I don’t have a slide hammer, so if necessary I’m going to turn the disc around, put three lugs on loosely and pull it off that way, I hope! Thanks again, not questioning your advice.
Brake caliper is metric, I think. I looked for some pictures, but I couldn't find any of my rear axle. You should bring a fairly complete set of tools, I would think. The diff housing cover bolts are 5/16" (1/2" socket), I think the caliper bolts are an M6 (so 10 mm socket). You shouldn't need a slide hammer. They should pull out very easily.
Also, download a manual for an 03 or later jeep from the site here, and read up on axle shaft removal. They go through the process fairly well. I say 03 and later, because I know the Dana 44 teardown instructions will be there (Rubicon)
Don't overthink it. The axle removal is very straightforward. When out, check the splines for straightness. There will likely be some wear primarily on the drive side of the splines. Some shininess and possibly a bit of indentation where the side gear rides is normal. If the splines are crooked/uneven, heavy wear/indentations, cracks, and of course anything broken, it is time to replace. Of course posting up pics for the peanut gallery to see can be helpful, too 
Well, this is a good day. The splines were perfect, never wheeled, looked brand new. The diff gears look great too. I’ll remove the tack welded spider gears and carrier and install the traclok carrier. Needs bearings, no biggie. $800 and super nice guy will help me with anything, even offered to do my regear front and rear for $900-$1000 (parts included)
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Score. Could just run it welded and let people look at you funny in parking lots 
—
There must have been a time
when we could have said no.
—
There must have been a time
when we could have said no.
Chirp, chirp, chirp!Score. Could just run it welded and let people look at you funny in parking lots
—
There must have been a time
when we could have said no.
Now I’ll be able to wheel over those concrete parking stops without worrying about breaking my turd!
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