Is There A Trick To Getting Pinion Out Of Dana 44

Well the pinion wins, I've changed my strategy to shopping for Dana 44 R&P 3:73. Like Glenn said the pinion is basically ruined at this point.



I carried on even after that damage was done. Got some grade 8 bolts, setup my hub puller again, torqued the puller down with impact wrench til it would go no more, heated the yoke as best I could with map gas, beat the puller with a really big sledge. Nothin!!!

If anybody would like a FREE Dana 44 tapered axle housing WITH PINION let me know

 

This is exactly what I had in mind....

 

One option would be to drag it down to an axle shop and pay them to pull it.

 

Jeez, everything I have must've leaked like a sieve or been worn out. I've never had trouble getting them out. Usually a couple sharp raps with a hammer does the trick. Definitely the above advice about heat the sides of the yoke quickly while under tension and giving the nut on the end a hard rap would've probably done the deal.

 

This whole saga reminds me of trying to extract a pinion gear from my Triumph TR8 with a Leyland diff. I took the nut and washer off, and put a small puller on the flange. The flange came right off. Then I tried to push the pinion out. It wouldn't budge. A few whacks of a brass hammer; didn't budge. I took the whole axle housing down to my brother's who has a 50 ton press. Well, after nearly 50 tons, I pretzled the end of the pinion shaft with a big "S" bend.
Upon a little more examination, I unbolted the 1/4" alloy thick seal retainer, and there was about a big old locknut hiding under there holding the pinion in the tapered bearings. One nut holding the flange, then a bigger nut under that for the bearings. I was used to 10 and 12 bolts, and D44s. Not how the British do it!
-Donny

 

I did finally give up since I pretty much destroyed the pinion... guess I hit it with my purse too hard

I solved my drama filled saga thru craigslist, $50 and this


Plus he wants me to fix his guitar... which needs, ahem... a bit of work, so I should make my $50 back plus another $400

 

Hard to believe yours is so stuck I just replaced my pinion bearings yesterday and my yoke came right off with a air hammer after carrier was out