Dana 44 thread repair

[spork2367]

Finally got around to fixing the stripped holes. Just redid them all. Used the cover as an alignment tool to drill. Heli-coiled back to M10x1.5. New grade 10.9 bolts.

[gtcollins@maxnet.co.nz]

Hi I have had to do mine as well I think the bolts are alitte sort maybe seem to be ok to start with then next time they start to pull the threads out I always use a torque wrench on them and I have long bolts now

Glen

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[spork2367]

Hi I have had to do mine as well I think the bolts are alitte sort maybe seem to be ok to start with then next time they start to pull the threads out I always use a torque wrench on them and I have long bolts now

Glen

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I ended up going with a 25mm heli-coil and a 30mm bolt. I was originally concerned with having to drill too deep to clear the tap for a 30mm insert, but with the bottoming tap I would have had plenty of room.

Regardless, the heli-coil is much stronger than the formed thread created by the tri-lobed thread forming fastener. Both in the percentage of thread, and the standard thread engagement vs. the weird engagement of the tri-lobed thread profile.

Part of the problem with those fasteners is that unlike a thread forming tap run in a modern CNC mill that is held in a rigid tap holder, the fastener relies on the threads formed after the start to pull the fastener in forming the additional threads, putting a lot of force on the first threads. That reduces as more threads are formed and the load is distributed over more threads. Modern thread forming for holes (not in a floating holder) utilizes the machines feed to control the depth and relies on the CNC control to control the lead and apply even force vs. some guy applying force or relying on the weight of the tool.

[gtcollins@maxnet.co.nz]

Don't know alot about manufacturing but have used heli-coil a lot and also know some manufacturers use them when they are making products I have another Dana 44 I am rebuilding for my ZR-1 so will be in to it in the future hope yours works out well for you

Glen

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[Jagdpanzer]

On the Dana 44s I've gone through lately I go back with heli-coils, 10 mm 10.9 studs bedded in the housing with red Loctite. Also switch the differential carrier retainer cap bolts over to ARP 1/2" studs. 17077


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[Jagdpanzer]

17078


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[gtcollins@maxnet.co.nz]

Very nice Phil maybe I should get some studs for mine I have got a car creation bat wing and also have one of his dana 44 housing coming so hopefully the housing will be ok when it arrives I also make solid spacers for the pinion instead of the shims

Glen

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[spork2367]

Very nice Phil maybe I should get some studs for mine I have got a car creation bat wing and also have one of his dana 44 housing coming so hopefully the housing will be ok when it arrives I also make solid spacers for the pinion instead of the shims

Glen

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I wonder what ever happened to the tooling for the car creations bat wing and case?

[gtcollins@maxnet.co.nz]

Not sure about the tooling would need quite few buys to make a run that where the problem would be

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