D44 IFS clutch pack replacement

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Apr 9, 2011 | 10:17 PM

6fifty_f1fifty

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From: San Diego

D44 IFS clutch pack replacement

Would you guys do this to get the cross pin out of a D44 IFS, or is there an easier way to get it out with out dismantling the whole thing?

http://www.ringpinion.com/Images/Tips/Interference.jpg

Apr 10, 2011 | 04:53 AM

tjc transport

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From: Marlboro Mental Hospital.

i would never do that to a gear set.
but then again, i would never have an IFS in anything i own, so i can"t say how hard it is to take apart.

Apr 10, 2011 | 07:30 AM

77mud

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No way in hell id cut the gears like that that's just asking for trouble... it the ring is in the way then mark the ring position on the carrier (not that it should matter but best to be safe than sorry) and pop the 10 or so bolts and drive the pin out

Apr 10, 2011 | 10:44 AM

6fifty_f1fifty

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From: San Diego

I just didn't want to screw with any ring/pinion alignment, so as long as I put it all back the same as how it was in there, I should be good then?

Apr 10, 2011 | 04:31 PM

77mud

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Quote:

Originally Posted by 6fifty_f1fifty

I just didn't want to screw with any ring/pinion alignment, so as long as I put it all back the same as how it was in there, I should be good then?

Yea the only thang you 'align' is how many shims are behind the bearings on the carrier sliding it side to side and on the pinion sliding it up and down

Apr 10, 2011 | 10:09 PM

6fifty_f1fifty

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From: San Diego

Managed to get it all apart and swap in the new clutch pack. Problem I am having now is I can't get the washers to go in with the spider gears (the ones that go between the two gears that hold the clutches) I got it to go together with a wooden dowel, but still can't get the washers in.

Any pointers, or "Crap I should have thought of that" ideas for how to put it back together?

Apr 11, 2011 | 06:18 AM

77mud

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Apr 11, 2011 | 12:01 PM

fatdan460

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From: utica il

wow, that is pretty effed up tech right there, granted that side of the gear isn't really engaging the pinion, but that has to take strength away from the ring gear. goofy.

Apr 11, 2011 | 03:13 PM

#10

6fifty_f1fifty

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From: San Diego

So I figured out how to get the spherical washers in behind the pinion mate gears. Seems there is a $120 tool to compress the clutch pack and Belleville plates to allow enough slack in the pinion mate gears to slide the washers behind them.

I wish I would have taken a picture of it in action, but what I did was use a grade 8 bolt with two large washers and two nuts to compress the assembly enough to slide the washers in.

Apr 13, 2011 | 12:56 AM

#11

Pkupman82

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From: Muskegon, MI (home)

Quote:

Originally Posted by 6fifty_f1fifty

Would you guys do this to get the cross pin out of a D44 IFS, or is there an easier way to get it out with out dismantling the whole thing?

http://www.ringpinion.com/Images/Tips/Interference.jpg

I have have seen and a heard of this being done on several occasions. I would have to agree it is pretty scary looking no doubt. But, I know of at least two axles that were recently built by a friend of mine (who is extremely knowledgeable and experienced with setting up gears) that had to have the ring gear clearanced for the cross pin. Both of which were c-clip type axles that he installed lunch box lockers in, in this case it was the only option. Typically when we need to do this, we'll rotate the ring gear around until it lines up with a spot to which you have to clearance as few teeth as possible. More often that not once the gears are set up properly, with the use of of marking paint we have noticed that the area that was ground down isn't even in the path of the pinion. It's still a good idea to deburr the area once the needed amount of material is removed. I know all you guys will probably think I'm crazy for saying this, but this practice is more common than you might think.
John