fr3db3ar
03-18-2006, 09:08 AM
This is my first attempt at a writeup so put it where you think it may belong.
Here's where it starts
http://i48.photobucket.com/albums/f207/fr3db3ar/Dscf0953.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0954.jpg
Pull all of your cover bolts but the top one and pop the cover loose with a weapon of your choice..I use a deadblow hammer.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0960.jpg
I had a leaky pinion seal too
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0961.jpg
I wondered why my pig got water inside and my antilock quit working....I found out why.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/2acd4d1f.jpg
Here's the inside with stock gearing and center pin turned so you can see the center pin bolt that has to be removed to get the center pin out. You need a E8 torx for this and it's easier if you take off the passenger carrier bearing bolts first to allow straighter access.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0963.jpg
For those who have never had your carrier out this is what a 44HD limited slip diff looks like disassembled.....except for that broken clutch plate...that's bad
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0964.jpg
Here's a closeup of one of the idle spider gears that was damaged by parts of the cluth floating around.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/a421f6ea.jpg
I didn't go into detail on extracting the carrier as that should be pretty self evident....take the 4 carrier bolts out and gently pry out the carier.
I also didn't go into detail on pulling the pinion. I used a pipe wrench to hold the yoke and a 1 5/16 socket to remove the pinion nut.. Changed the pinion seal and reassembled in reverse order with new bearings. I did add an extra shim under the pinion bearing to help make up for the difference in pinion gear size...it worked for me.
Here is the new pinion installed (4.10 gears...stock were 3.73) and the open carrier with the driver side part of the aussie installed along with center gear and c-clip cover. IMPORTANT.....ENSURE THAT YOU INSTALL YOUR STOCK THRUST WASHERS ON THE LOCKER FOR PROPER CLEARANCING. step by step photos You can also see the gear pattern from my gear install....It's not bad so I'll live with it....I set pinion preload to 19 in/lbs and backlash to .006" (first try :mrgreen: )
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0966.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0967.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0968.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0969.jpg
Here is the carrier turned and ready for the center pin install
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0970.jpg
Dont forget to install the pins and springs per instructions with the kit
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0972.jpg
Slap some RTV sealant on the cover and put it back on
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0973.jpg
All comments are welcome. Hope this helps someone.
Here's where it starts
http://i48.photobucket.com/albums/f207/fr3db3ar/Dscf0953.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0954.jpg
Pull all of your cover bolts but the top one and pop the cover loose with a weapon of your choice..I use a deadblow hammer.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0960.jpg
I had a leaky pinion seal too
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0961.jpg
I wondered why my pig got water inside and my antilock quit working....I found out why.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/2acd4d1f.jpg
Here's the inside with stock gearing and center pin turned so you can see the center pin bolt that has to be removed to get the center pin out. You need a E8 torx for this and it's easier if you take off the passenger carrier bearing bolts first to allow straighter access.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0963.jpg
For those who have never had your carrier out this is what a 44HD limited slip diff looks like disassembled.....except for that broken clutch plate...that's bad
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0964.jpg
Here's a closeup of one of the idle spider gears that was damaged by parts of the cluth floating around.
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/a421f6ea.jpg
I didn't go into detail on extracting the carrier as that should be pretty self evident....take the 4 carrier bolts out and gently pry out the carier.
I also didn't go into detail on pulling the pinion. I used a pipe wrench to hold the yoke and a 1 5/16 socket to remove the pinion nut.. Changed the pinion seal and reassembled in reverse order with new bearings. I did add an extra shim under the pinion bearing to help make up for the difference in pinion gear size...it worked for me.
Here is the new pinion installed (4.10 gears...stock were 3.73) and the open carrier with the driver side part of the aussie installed along with center gear and c-clip cover. IMPORTANT.....ENSURE THAT YOU INSTALL YOUR STOCK THRUST WASHERS ON THE LOCKER FOR PROPER CLEARANCING. step by step photos You can also see the gear pattern from my gear install....It's not bad so I'll live with it....I set pinion preload to 19 in/lbs and backlash to .006" (first try :mrgreen: )
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0966.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0967.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0968.jpg
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0969.jpg
Here is the carrier turned and ready for the center pin install
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0970.jpg
Dont forget to install the pins and springs per instructions with the kit
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0972.jpg
Slap some RTV sealant on the cover and put it back on
http://i48.photobucket.com/albums/f207/fr3db3ar/44HD%20Aussie%20Install/Dscf0973.jpg
All comments are welcome. Hope this helps someone.