Dana 44 Axle Tubes

[Rubicon Josh]

I was out wheeling west of rocky mountain house a couple of weeks ago, and when I got back to Brooks where I live I noticed that a loud crunching noise came from my front end. Immediately my mind began to race as to what the sound might be. My heart pounded and sweat trickled down my forehead as I concluded that I must have snapped an axle or worse cratered my diff.

I found time last night to finally open things up to survey the damage. I started with the diff cover. To my surprise, the synthetic gear lube poured out looking like new, with no traces of sludge, water, or bits of metal. A close inspection of the ring and pinion still in the diff case showed absolutely no signs of damage. To say the least I was very relieved.

Now knowing that the differential is in good shape I prepared myself for the discovery of a broken passenger side axle shaft. I removed the wheel and brake assembly and proceded to remove the brake disk. When I attempted to pull the disk away from the hub, the two seemed to be pressed together or seized. I finally managed to bang it off of the outer axle and then easily pulled the axle assembly out of the axle tube. I was prepared for the axle shaft to be easily removed, because I thought it would be twisted off at some point. However, when I removed the shaft it was complete, and had absolutely no damage. Now I was puzzled. If it wasn't the diff or the axle, what was the noise I was hearing?

I had almost forgot about the bearing carrier and hub that seemed to be seized into the brake disk. Sure enough, when I rotated the bearings they were dry, noisy and hard to move. I have to assume that this was the source of the very loud crunching. The u-joint on the axles seem to be in good shape with no excess play and all other components appear fine so I am sure that it is the case of simply doing a bearing and seal swap.

And now my questions;

I wonder... is it normal for the bearing carrier and hub to be so difficult to remove from the brake disk?

Is there supposed to be an outer seal set inside the axle tube?

I have about 1/4" of mud and debrit inside the axle tube. I know that the inner seal at the differential is doing it's job because there wasn't any mud or water in the diff. Is there an easy way for me to clean the axle tube without pushing the mud back into the diff? Is there an easy way to clean the axle tube without removing the diff carrier? And finally is there an easy way to clean the tube with out water so as not to get any inside the diff?

Also when re-installing the axle shaft is there a way to install it without damaging the inner seal? I really don't want to pull the diff carrier out if I don't have to.

Hope you guys liked my narrative. Haha. Any advise would be appreciated as usual.

Josh

[hps4evr]

first. the rotors always like to seize to the hubs. no biggy. when they are seperate put some anti-seize on the face of the hub where the rotor contacts it.
second. the best way to clean the tubes is to remove the carrier and change seals too all at once. you can buy outter axle tube seals as well to keep crud out of the tubes. we have them at national.
final. when reinstalling the shaft just try to aim it towards the middle of the tube. 9 times out of 10 it goes right through with no issues and right into the diff. be sure to clean the seal surface on the axle as well. little bit of light sand paper works just to take and burrs or grooves away.
add some anti-seize to the hub bolts too, trail repairs will be muchnicer down the road.
good luck
eric

[cuzican]

I've had some success removing the crud in the tube using a washer screwed onto the top of a broomstick.  Washer should be a bit smaller than the tube ID so that you can get all the way in to pull out.