TJ D44 damage

[WILDTJ]

Well my rear diff had been making some clunking noises since I bought it when turning, and changing from forward to reverse, or vice versa. I finally decided to investigate the other day after my diff noises were getting worse and ongoing whilst underway. Not what I wanted to hear being unemployed and on a very tight budget.

Pulled both axle shafts and they were fine, on opening the rear diff I found the top and bottom spider gears were missing great chunks out of the teeth, side gears were intact. So I ordered a new set of gears, cheaper getting direct from Summit in USA.

First problem was I could not get the cross pin shaft out of the carrier whilst the ring gear was still attached. Where I am renting has a pit in garage so I improvised with a ratchet strap down through timbers covering pit hole and attached to I beam to keep leverage on carrier.





So my parts arrived 4 days later, but now the fun began as I had ordered for an open diff and on removing the carrier I now find that the carrier is an LSD, woohoo!! After dismantling the spider gears I find the root of the problem was the dished spacer against the side gears was either in 2 or 3 pieces. No doubt these pieces were jamming against the plates, jamming the axle drive and so the next weak link in the chain was the top and bottom spider gears.



Due to my lack of budget, and good state of the side gears showing only a little wear pattern, I have decided to order new clutch packs and use the new top and bottom spider gears to replace the old destroyed ones. At least this will keep me going until upgrading with a full locker once I am back in work.

[fesm_ndt]

I have an open centre.... If there's any bits I can salvage out of it you can use let me know

[greeno]

I've got 4 or 5 stock LSD carriers here mate more then happy to pass one onto you mate I'm on the sunny coast qld


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[WILDTJ]

Originally Posted by fesm_ndt

I have an open centre.... If there's any bits I can salvage out of it you can use let me know

Cheers fesm

[WILDTJ]

Originally Posted by greeno

I've got 4 or 5 stock LSD carriers here mate more then happy to pass one onto you mate I'm on the sunny coast qld

Cheers greeno, wouldn't use second hand clutch packs, and got new ones on the way but depends on how little wear/low km's the side gears have got, rather replace with something alot newer to match brand new top and bottom gears, or matched set.

[WILDTJ]

Well the company I purchased the Trac-Lok clutch disc kit from ended up advising me it was back-ordered, then got update to a different date again, so bit the bullet and cancelled the order. Thankfully Wooders came to my rescue, actually had kit in stock, and ordered express post it arrived overnight to Adelaide.

This was not a fun job seeing I did not have any bolts and washers to squeeze the side gears into the carrier to make room for the smaller gears top and bottom. With a lack of ways to improvise I just used a punch in the lands on the small gears tapping them in bit by bit, alternating between each of them.

Once they were finally in I could use a clamp and the old broken spider gears to squeeze the side gears out and make room to sneak in the top and bottom thrust washers.


All back together and full of right oil, plus an oil change for front diff, test drive this arvo and runs great, even chirping the tyres on a slow u-turn, very happy.

[rang0]

How much does it cherp? I thought id be awesome and welded up a diff because all the spiders were broken and it cherped every time i turned. You havnt locked it have you? Did you put the additive to the oil?

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