D44 carrier removal - HELP!!

[Panoscopic]

I'm installing a Powertrax Lockrite in my TJ. I've got 3.73 gears and have to remove the carrier to remove the ring gear and pinion. My problem is I've got everthing off - axles are out, but the carrier just stuck there. I can't seem to pry it out. Anybody have this problem and know what to do?

[reddog]

Been a while since I pulled a dana apart so I won't be much help and I know this won't help you now BUT these people have always been very helpful. Maybe there is something on the site or if you need help in the future...

http://www.ring-pinion.com/home.html

Kerry

[porkchop]

You took off the caps right? You also removed the pinion nut? Are you going to reuse the gears or change them? I remove them buy taking a rubber mallet and tapping on the pinion shaft. They pop right out. Not the most recomended way but effective.

[Panoscopic]

Make that Powertrax Noslip.

One reason I got a in-carrier unit because I thought it would be easy to install. It turns out that my 3.73 ring gear extends over the pinion shaft so it requires that the carrier be removed so that the ring gear can be removed. Needless to say, I'm a bit dissapointed that the process is more complicated than I anticpated, but that's usually the way these things work out, right?

Porkchop: Yes, I've got the caps off. The carrier should slide right out I thought, but it just seems to be in there rather tight. Before I got banging on it, I wanted to check that I've done everything.

I've also been told that even thought I'm touching the ring gear, no lash adjustments have to be made. I hope this is the case, otherwise I'll have to end up going to the pros after all. The pinion stays in - if I could get it off, I would not have to do this at all!

[Crazy_Jeepman]

The carrier can be a real bear to remove. I put a box end wrench on a ring to carrier bolt rotate it so it comes to a stop at the top of the diff housing, then I take a pry bar and get a bite off the bottom of the carrier, pry as to roll it out. The carrier will move doing this, however you will then need to pry from the top and bottom as well as be sure the bearings are comeing out straight if it becomes uneven it will just stay there. Have fun getting it out, and then if you think that was fun wait till you put it back in. Ok its not that bad, there are worse jobs just none come to mind at the moment! Good Luck ;)

[fulmetal]

Ever noticed those two holes just on either side of the cover? Those are made just for you in your situation, You place a diff spreader in there and pry apart the axle tubes. Never had to use one on my rig, but thats what they are for. As to where you would rent one you would have to call around. Good luck they can be a bear !!!!! :(

[88GW]

I installed a Powertrax in my 88 GW and ran into having the issue you are having, a thick ring gear interfering with the cross-shaft. I am going to assume that you have already removed the C-clips if it is equipped with them. If it is not equipped with c-clips you need to use a slide hammer and slide out the axles about six inches from the axle tube. After the caps are off the carrier you then should easily be able to use a crows foot to pop the carrier out. It shouldn't be that difficult. More questions e-mail me at loujad@aol.com

[River Beast]

IF you are haveing that much problem getting the carrier out by prying.... do what Fulmetal said.... go to NAPA of some place to borrow a case spreader. You will need it for install as well so keep it handy till your done.

Mine was a bear, too... but I got it with a 3' pry bar and a hand sledge (to the pry bar of course) :D

[88GW]

Sorry I didn't see your axles were already out. Case Spreader sounds like your solution

[Panoscopic]

River Beast/88GW:

I just talked with PowerTrax tech support - they said exactly the same thing. Either pry it out or rent a case spreader. Putting it back they said I would have to hammer the washer in - does not sound like what I want to do so ideally I should get the spreader. I've called around a few places - rental companies, several NAPA shops, autozone etc. Nobody seems to have one to rent.

[ October 15, 2001: Message edited by: Panoscopic ]

[River Beast]

Find a shop that rebuilds rearends.... ans start sweet-talkin' :D

Going back in isn't that much more difficult.

[Panoscopic]

River Beast:

Going back in - do you have to pound on it, or can you let the caps smooth it in? Also, any problem making sure the shims go in at the same time?

[River Beast]

ummm... I my Dana 44, the shims were between the carrier and the carrier bearing... no loose shims to worry about. If you have loose shims, they must be put back in the SAME EXACT WAY as you took them out... with the carrier. Slowly(using a deadblow mallet) tap in each side of the carrier a little at a time until fully seated... good luck...

oh...one more thing... make sure as the ring meshes with the pinion gear, tha they do not bind as you are tapping it in....

[ October 15, 2001: Message edited by: River Beast ]

[88GW]

Let us know what happens. I would try again and see if you could get a crows foot in there and pop it out. Mine was pretty snug but I can't imagine having to use a case spreader on a Dana 44. I thought mainly Dana 60's required spreaders. Hope all works out alright. If not try a shop as RB stated.

[Panoscopic]

Hey guys, success! I got it out with a 30" prybar. It was not as hard as I thought - she slowly slipped out as I gently went from side to side. Use a big bar and treat it like a lady!

Now, my vice is not big enough to hold the carrier, and trying to get the ring gear bolts off with two wrenches with the carrier between my knees just won't work. I just might have to go to a shop after all if I can't figure out how to work it.

Wow, thanks guys for all the help. It really gave me the confidence to go do it.

[ October 15, 2001: Message edited by: Panoscopic ]

[River Beast]

GREAT JOB!!!! I knew you could do it.... now as for the ring bolts...find a buddy with a compressor and zap 'em off. ;)