Dana-44 forward pinion bearing removal

[68 TT]

Is there any trick to removing the pinion gear from a Dana-44 front axle?

I have the axles & carrier out, pinion yoke & seal off and the pinion gear is loose & moves around but I can't get it to break free of the forward pinion bearing.

With all the other axles I have pulled apart the forward bearing just about falls out once you take the yoke off & remove the seal.

I gave it a few smacks with the 3-pound hammer and no movement.

I have it on the 20-ton press and don't want to put any pressure on it until I make sure there isn't some retainer clip or something else holding it in.

The pinion was very loose when it was still assembled and moved about 1/4" side to side. The pinion yoke was also heat discolored on the edge that touches the forward pinion bearing. From the blue oxidation color it saw at least 540 degrees on the yoke. I'm afraid the pinion bearing inner race may be welded to the pinion bearing.

Is there something I'm missing that will let it drop out or should I just put some real pressure on it and see if it breaks free?

[LONGHAIR]

There is probably just a burr on the splines or it may just be siezed from the heat that you mentioned.
Either way, there is nothing that is suppoed to be holding it in there.

[68 TT]

Originally Posted by LONGHAIR

There is probably just a burr on the splines or it may just be siezed from the heat that you mentioned.
Either way, there is nothing that is suppoed to be holding it in there.

Good to know. Thanks for the help. I will put some pressure to it on the press and see what gives first.

[dropd80s]

Originally Posted by longhair

there is probably just a burr on the splines or it may just be siezed from the heat that you mentioned.
Either way, there is nothing that is suppoed to be holding it in there.

x2

[68 TT]

Got it out. Took a die grinder and a chisel to break apart the inner race so the pinion could get past the outer race & roller bearings.

Housing is in good shape still. Just need to see if I can get the inner race separated from the pinion gear to evaluate the condition of the gear.

Worst thing that happens is I have to get another set of gears for it.

I will get some pics of it when I get home.

[68 TT]

Took nearly three hours but I got the pinion out out without hurting the rear end housing or doing any additional damage to the pinion gear.

The pinion gear is heat discolored for about an inch rearward of the forward bearing. I don't know if it is enough to weaken the pinion gear or not. Most likely it will fail under heavy load so I am going to look for a better set of gears.

The roller bearings were hammered and not rolling too well if at all.

I will try to get the inner race off without hurting the pinion gear and see how it looks. It is being pretty stubborn and may not come off.

[LONGHAIR]

When the bearings are that hammered, the gears are shot anyway.
Persistence is great, but there is a time to give up the fight.....there really is nothing to gain.

[68 TT]

Originally Posted by LONGHAIR

When the bearings are that hammered, the gears are shot anyway.
Persistence is great, but there is a time to give up the fight.....there really is nothing to gain.

I only kept at this one because it has to go into my truck so the matched set of 5.13 axle assemblies that are in my truck can go to the new owner. He has already given me a deposit on them so I don't want to keep him waiting any longer than I have to.

I am going to put the bare housing into the truck with no carrier, gears, axles or locking hubs and get on with the rear axle work.

The 14-bolt with the 4.10 gears is in good shape and once swapped will get me back on the road and then I can deliver the old 5.13 axle assemblies to the new owner.

I will keep looking for a complete 4.10 geared front axle to replace this one with.

I have about 3 or 4 months to find a 4.10 front axle assembly to replace the damaged part with so putting the hammered one in will buy me some time to find a decent one.