Well, I finished the teardown of my read Dana 44 and ARB. I narrowed the excessive play down to the splines on my stock axles. The ARB looks great except for the spider cup shims and the splined gear shims. They just look like they should be replaced.

I also ruled out any current component as the source of the metal chunks I found inside. They must must be left over from prior damage and never cleaned out well. The chunks, however have left behind minor damage on all my races, even those installed on the axles just last spring. The inner pinion bearing rollers have scratches on them as well. So it looks like I'll be replacing all the bearings. The gears look good enough for me to reuse, but I'm going to get a second opinion on those.

That's what I know. What I don't know is, how to install the new pinion races, do I really need an axle housing spreader to install the new carrier bearings and shims, how to remove the old pinion bearing (Cut it off???)and I'm not sure what I don't know yet? And what all tools I'll need???

Then I'm wondering if I can upgrade the splined spiders within the ARB to 35, and go up a notch on the new axles.

I had previously started an article in Tech Reports, and will continue to update when I have time.

We can all benefit from your sharing of these experiences in your technical report. Good Luck! Also, I have a Dial indicator for your backlash set-up if you want to use it.

My neighbor and I used the press to remove and install the new bearings from his pinion. As far as the races I think he gently hammered them. Sounds crud but it seemed to work. or you can buy the tool. your call??

Thanks Guys. That takes care of two of the things on my list. Once I get my parts, I'll have to stop down at your place Kevin. And Gary, maybe we could meet up for lunch and I could pick up that dial indicator from you.

I also have a possible line on a diff housing spreader.

I ordered CrMoly axles, master install kit and parts to rebuild my ARB yesterday. My gears look good enough to reuse. It could take up to 2 weeks for the ARB parts to arrive.

Hey Gary - What about that offer to video tape the rebuild?

ANYONE HAVE ANY IDEA WHERE I CAN FIND AN INCH POUND TORQUE WRENCH, WORKING RANGE BEGINING AT 0 INCH POUNDS? Rent or buy!
The specs on my pinion preload, with used gears, is 6-9 in lbs, and like 12-25 in lbs for new gears.
I can't find one anywhere in town. I can find them at Grainger and Sears, but 7-14 days shipping.
UNREAL!!!