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Thread: WORN SPLiNES DANA 44 AXLE SHAFT

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    WORN SPLiNES DANA 44 AXLE SHAFT

    pulled my rear axles on my '04 tj rubicon to replace leaky seal and found that the passenger side shaft has a worn spline but the driver's side shows no wear. any idea what caused this?


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    This is technically possible on very high mileage shafts. However, if one side is fine and the other is not, it is because there is misalignment between the axle shaft and the carrier (typically a bent housing) or the shaft itself is slightly bent.

    You may want to remove the carrier and inspect the side gear as well. Side gear splines may also have excessive wear.
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    One more possibility is the shaft did get properly treated for the correct hardness / depth.

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    Your lucky when I have to pull axle shafts this is what I get

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    Quote Originally Posted by Stickybongsmoking View Post
    This is technically possible on very high mileage shafts. However, if one side is fine and the other is not, it is because there is misalignment between the axle shaft and the carrier (typically a bent housing) or the shaft itself is slightly bent.

    You may want to remove the carrier and inspect the side gear as well. Side gear splines may also have excessive wear.
    Bent axle housing causing spline wear?
    Who woulda thought of that!

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    thanks for the responses guys
    i don't think that a bent housing or axle would have caused such even wear all the way along the mating surfaces, i would expect to see signs of wear in the root of the spline (if that makes any sense) but there is none.
    so it looks like i'll be pulling out the carrier to see what kind of shape the spline is in and then decide what needs to be done from there.
    unfortunately it's and air locker so parts will more than likely be pricey with my luck, lol!

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    Quote Originally Posted by onehoser View Post
    thanks for the responses guys
    i don't think that a bent housing or axle would have caused such even wear all the way along the mating surfaces, i would expect to see signs of wear in the root of the spline (if that makes any sense) but there is none.
    Root = minor diameter. If the mating splines never touch the minor diameter of the axle shaft, wear would be unlikely there.


    Quote Originally Posted by onehoser View Post
    so it looks like i'll be pulling out the carrier to see what kind of shape the spline is in and then decide what needs to be done from there.
    unfortunately it's and air locker so parts will more than likely be pricey with my luck, lol!
    That is the next thing to check. If the side gear splines look good, I'm going with an inadequate depth of surface hardening treatment or improper after treatment of the alloy on the shaft. It is not common but it does happen. I have seen it before on some aftermarket shafts.

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    turns out the internal spline on the carrier is badly worn so i decided to replace the locker with an eaton selectable e-locker rather than the more expensive factory locker

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