Rear Axle questions, G2 Core44 pinion

Corky1071

Corky1071

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Hoping for some advice on the brand new G2 Core44 rear axle I just recently installed. Purchased brand new, still on shipping crate G2 Core44 with 4.56's and ARB locker. Installed with new Savvy DA UCA's, track bar, brand new brakes complete and made new brake lines. Still in the break-in period, I've only put about 300 very easy miles on it so far. Has not seen the freeway yet, and I have adhered to "proper break-in" process (Drive 15-20mins, let cool for 20-30mins, no speeds over 50, light pedal, Working up to 30 min drive, yada yada yada). So last week, on a short trip (5 miles) to airport to pick up wife, make right turn and loud "pop" & VERY loud rotational clunking. Immediately pull over & flatbed brought it home. (Awesome Neighbor offered to go get wife and took us home the 5miles)

So Jeep is back up on jack stands in driveway, took it apart and this is what I find. Outer pinion bearing gone, race falls out, no big deal right? Here are my questions that I hope some of the more experienced gear guru's can answer. The outer bearing and race look to have gotten too hot, but nothing else.
1. Is there a missing oil slinger/baffle that should've been there to force oil up to outer bearing? And yes, oil level was correct. 1st pic is exactly what came out.

tempImageBB3yCc.png



2. Do I need to worry about the small rolling on the pinion splines?
tempImage5fD70V.png


tempImageE7Vsi0.png



3. Which size socket is supposed to be used for pinion nut?!!? 1-5/16 has slop & a 32MM needs the help of a hammer to go on :mad:
tempImageBMnRXv.png


tempImageu0KPOE.png

Here's outer bearing & race
tempImageUtbcV5.png
 
Unfortunately, no warranty from G2. I bought it off marketplace. But they did provide a build sheet…

IMG_6089.jpeg
 
My biggest concern is I have all new parts to reassemble, but hesitant to do so if there’s something missing.
 
Corky1071 said:
Hoping for some advice on the brand new G2 Core44 rear axle I just recently installed. Purchased brand new, still on shipping crate G2 Core44 with 4.56's and ARB locker. Installed with new Savvy DA UCA's, track bar, brand new brakes complete and made new brake lines. Still in the break-in period, I've only put about 300 very easy miles on it so far. Has not seen the freeway yet, and I have adhered to "proper break-in" process (Drive 15-20mins, let cool for 20-30mins, no speeds over 50, light pedal, Working up to 30 min drive, yada yada yada). So last week, on a short trip (5 miles) to airport to pick up wife, make right turn and loud "pop" & VERY loud rotational clunking. Immediately pull over & flatbed brought it home. (Awesome Neighbor offered to go get wife and took us home the 5miles)

So Jeep is back up on jack stands in driveway, took it apart and this is what I find. Outer pinion bearing gone, race falls out, no big deal right? Here are my questions that I hope some of the more experienced gear guru's can answer. The outer bearing and race look to have gotten too hot, but nothing else.
1. Is there a missing oil slinger/baffle that should've been there to force oil up to outer bearing? And yes, oil level was correct. 1st pic is exactly what came out.

View attachment 482916


2. Do I need to worry about the small rolling on the pinion splines?
View attachment 482919

View attachment 482920


3. Which size socket is supposed to be used for pinion nut?!!? 1-5/16 has slop & a 32MM needs the help of a hammer to go on :mad:
View attachment 482921

View attachment 482922
Here's outer bearing & race
View attachment 482926
Click to expand...

Wow, that's very unfortunate. I would suspect the pinion preload was set way to high which will cause the bearings to burn up like yours.

The pinion is a little confusing to me but my guess is because it is an aftermarket housing. I'm not familiar with the specifics of the G2 products other than they are the 4 wheel parts house brand IIRC. The reason I say the pinion is confusing is because TJ Dana 44's use shims, not a crush sleeve. As you can see in the picture there are pinion preload shims there but it also looks like the piece to the left of the shims might be a part of a crush sleeve eliminator. I'm just not sure.

I wouldn't worry about the splines too much as long as the yoke slides on and off ok.

The stock pinion nut size is 1 1/8".

That bearing got roasted, not just hot.
 
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hosejockey61 said:
The pinion is a little confusing to me but my guess is because it is an aftermarket housing. I'm not familiar with the specifics of the G2 products other than they are the 4 wheel parts house brand IIRC. The reason I say the pinion is confusing is because TJ Dana 44's use shims, not a crush sleeve. As you can see in the picture there are pinion preload shims there but it also looks like the piece to the left of the shims might be a part of a crush sleeve eliminator. I'm just not sure.

I wouldn't worry about the splines too much as long as the yoke slides on and off ok.

The stock pinion nut size is 1 1/8".

That bearing got roasted, not just hot.
Click to expand...
Crush Sleeve Eliminator is correct, looks like G2 called it a "Dana 44 rear solid spacer" according to build sheet.

I might try to get stock pinion nut, because the one that came in today doesn't fit any of my sockets. Unless someone knows of a size between 32mm and 1-5/16...

I also realized I need to replace the seal housing for the ARB locker, copper tube cracked when I removed carrier. So that needs ordered before I put it back together.
 
Corky1071 said:
Crush Sleeve Eliminator is correct, looks like G2 called it a "Dana 44 rear solid spacer" according to build sheet.

I might try to get stock pinion nut, because the one that came in today doesn't fit any of my sockets. Unless someone knows of a size between 32mm and 1-5/16...

I also realized I need to replace the seal housing for the ARB locker, copper tube cracked when I removed carrier. So that needs ordered before I put it back together.
Click to expand...

Find a 1 5/16 6 point socket and it will be fine. Where is the line broken? I can repair it if you like, I've done many. At least you'll have a spare that way.
 
mrblaine said:
Find a 1 5/16 6 point socket and it will be fine. Where is the line broken? I can repair it if you like, I've done many. At least you'll have a spare that way.
Click to expand...

Will acquire a 6 point 1-5/16 socket this week.

The line cracked at where it’s soldered to housing, I might’ve been a little rough with it when I removed it… (Of course I was on my back on the creeper) It’s no longer attached. I am very appreciative of the offer though, thank you! @mrblaine

Lucky for me, the wife says when we move I get to have a lift in the shop; but only after she gets power wood splitter 😉
 
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Well it’s about time I finally completed my 500 “break-in miles” 😂 (Truth be told, the Jeep only gets driven 1 day a week because the work rig comes home with me). But inspect of gears looks good, only the minor silvery glints attached to drain plug magnet. I can listen to the stereo again while driving.

IMG_6302.jpeg


IMG_6301.jpeg
 
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hosejockey61 said:
Wow, that's very unfortunate. I would suspect the pinion preload was set way to high which will cause the bearings to burn up like yours.

The pinion is a little confusing to me but my guess is because it is an aftermarket housing. I'm not familiar with the specifics of the G2 products other than they are the 4 wheel parts house brand IIRC. The reason I say the pinion is confusing is because TJ Dana 44's use shims, not a crush sleeve. As you can see in the picture there are pinion preload shims there but it also looks like the piece to the left of the shims might be a part of a crush sleeve eliminator. I'm just not sure.

I wouldn't worry about the splines too much as long as the yoke slides on and off ok.

The stock pinion nut size is 1 1/8".

That bearing got roasted, not just hot.
Click to expand...

G2 44s are based off of JK 44 stuff that is why you see the crush collar eliminator.
 
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