Metalflames

Picked up an XJ dana 44 yesterday and started the tear down. First issue that had me scratch my head is how the carrier just falls in and out with no effort. Second is the damage between the carrier / axle tube and the outer axle bearing. All the damage is localized to one end of the carrier and the tube. during my inspection it seams there was some weld that had burned through from the case through the axle tube. I am assuming the bits of steel I found had broken away from that. I haven't found any other damage to any gears or the carrier but I have yet to break down the carrier completely. Is the damage to the end of the axle tube an issue?
http://s765.photobucket.com/user/fra...show/dana%2044

SeriousOffroad

The damage appears to be as a result of a broken shaft.

Do a very thorough inspection of the carrier and side gears before deciding whetheror not to re-use 'em.

There's a tremendous amount of energy released when a shaft snaps and the shock can damage adjoining parts.

Metalflames

It may be possible. From what I know the rear was pulled at a junkyard and from the looks it was there a while. The only other discrepancy is that the axle bearing on the damaged side was a TIMKEN and all of the other bearings in the rear were KOYO. I assume the KOYO's were OEM. I'm trying to imagine how a stock XJ would break an axle shaft on a Dana 44.
For my build I would be replacing the carrier for a 3.92 and up set up. Upon further inspection I found some wear on the thrust face (?) perpendicular to the bearing journal. Should the chewed up axle tube be an issue? Also the fact that there seems to be no preload what so ever has me puzzled. Any ideas? I may have to bring the rear to a specialist to have them give it a once over.

SeriousOffroad

Any axle shaft can break at any time. a spinning wheel that suddenlty gains traction is one of the most common causes.

Lack of pre-load is probably a result of either bearing wear over time or incorrect set-up/assembly.

The tube isn't a problem.

The different bearings and the damge in the pics is a dead-give-away that one axle was already replaced.

Checkout my site for upgrades when you're ready to get started.

Metalflames

I want to be certain that everything is in the proper mechanical limits before proceeding with building the differential. But I am having a hard time finding all the specs I need. At this point I am less concerned with how it happened and more interested in if the diff is any good. No sense in dropping money into something that is going to fail.

SeriousOffroad

I understand.
You're housing is fine, I wouldn't hesitate to use it.