Here is the problem, I have a waggy Dana 44 rear end with a mini spool. I have snapped the axle off in the carrier and part of the axle is still in the axle tube so I can not pry the carrier out of the housing. Also the rig gear hangs over the carrier pin so I can’t get the carrier pin out to disassemble the mini spool to drive the axle out from the opposite axle tube side.
Any help here would be dam good the sawzall is starting to look good…..

Magnet taped to the end of a wood dowel will work as long as the splines aren't twisted a bit inside the spool.

If the gear is only overshadowing the pin a little bit, you can grind the end of a tooth off to provide clearance for the pin to pull out. I had to do this and have been running that way for 3 years since. No problem with the gear cuz the part that was ground off was not in the gear contact pattern area.

I tried the magnet, and the gear over shadows the carrier pin by a good inch, I have also tried to heat up some PVC pipe and shove it over the axle shaft and let it cool and pull it out, but that did not work...

Well, grinding won't work. Can you get the broken part to go further into the carrier?

I dont think so there is about 2 inches sticking out into the tube from what I can tell looking down the tube. I will try see if it seated into the spool..

you got a welder, a long piece of steel that will reach the axle? If so, you can rig up a tool to get it out. Put a lot of tape on the steel except for the ends so it does not weld itself to the housing.

you got a welder, a long piece of steel that will reach the axle? If so, you can rig up a tool to get it out. Put a lot of tape on the steel except for the ends so it does not weld itself to the housing.



we have done that on the trail before! we usually use a magnet on a stick but it didn't work one time because it was super stuck. the welder idea worked great!



one thing i would change though is to put a piece of pvc to the broken part and then put a metal rod through it so that you cant touch any other part till you get to the nub. this way you cant get it stuck to the bearings or the spool. then put your arc cables onto it an pull it out!




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Ah, piece of pvc....even better!

cant you use 2 car batteries in series with jumper cables also. I say this in a video trail fix they hooked the batteries together then stuck the steel into the pvc and put the ground on the peice of steel and then struck the positive to the pumpkin 4 or 5 times till it welded it and pulled it right out. thought maybe this would work for him if he didnt have a arc welder handy

rig somthing up out of ruber or any thing that will center its self in the tube with a small hole in the center, then take some small tubing or 1/2 SCH 40 pipe, and tack a drill to the end of it and try drilling the center of the shaft it should be softer in the middle.
once you have a good size hole ( 1/4-5/16 ) you could try tapping it by welding the tap to another piece of tube or pipe then you could tap a thread into the shaft.
then take a bolt welded to a the tube and try threading it into the shaft and like a small slide hammer pop it out, its alot of work but better than destroing your carrier, jason.

I dont think so there is about 2 inches sticking out into the tube from what I can tell looking down the tube. I will try see if it seated into the spool..

Another approach is to simply lasso that stub using a choker made from a length of PVC and a loop of small cable run thru a hole in the end of it. Once that loop gets over the stub start twisting the pipe and wahlah. :smokin:

Are the spools hollow threw them if so I had to do this with my ox when I snapped once. Take the other axle side out and push on the nub form the other end with a metal rod

Hay thanks for the info, but I have a wire feed welder so I will try the pvc and a couple of car batteries that seems like a good Idea thanks I will try it tomorrow.

the car batteries should work just fine. just get enough to make it hot!

Been there done that, but in my case I had a LockRight. Sucks, doesn't it? Do yourself a favor and get a full spool when you are done so you don't end up in the same situation.

Someone asked above about knocking it out from the other side, won't work with a mini-spool because it still uses a cross-shaft.

And also he is right, you can't grind the teeth, the crosspin is way behind the ring gear.

so did you ever get the saft out of that thing?

This happened to me too... Only I twisted the axles splines 3 teeth...

Take off the bearing caps... Use a cut off wheel... and cut the bearings off the carrier. If that doesn't give you the clearance you need to pull the carier... Didn't in my case... Use that same cut off wheel to to cut the axle off at the carrier... Once you get the carrier out.. it's alot easier to monkey with. Take the Ring gear off etc...

Good luck... mine was an royal PIA.

later...

You can also use welding rods and weld them end to end. Feed that down in a piece of pvc until you reach the axle then use either an arc or the batt. & jumper cable method to weld it to the axle shaft then pull it out, an attachment to a slide hammer of some sort can also help.
EDIT: If you really want to get fancy you can use a piece of steel rod and an attachment to a slide hammer or some sort of loop to allow a sledge swing and pull, then get yourself a welding rod. Cut part of the welding rod off (preferebly an inch below the area thats not coated in flux for the clamp handle) then mig the filler rod (the bare steel area to your steel rod) slide the contraption down a piece of pvc and use either an arc or batt. setup and weld it fast. This way you will have a SOLID piece to hammer on.

I like this idea!

Once I pulled my carrier... We had to take the detroit apart and use a HF press to push the broken shaft though...

My only concern is the rod wouldn't stand up so the punishment of a slide hammer...

You can also use welding rods and weld them end to end. Feed that down in a piece of pvc until you reach the axle then use either an arc or the batt. & jumper cable method to weld it to the axle shaft then pull it out, an attachment to a slide hammer of some sort can also help.