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Old 03-09-2017, 09:20 AM   #1
Zackaddict
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Default Scout 800 Rear axle surprise

While deep cleaning some more on my Scout 800 I noticed that the rear axle pumpkin was leaking oil.

I opened it up and it had barely any oil in it and the oil that was in it was basically chrome it had so many metal flakes in it. It looks like the bolts holding on side in have all come loose over time and have almost all broken up inside it. They're just one bolt in still and it's barely in there.
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The one bolt
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Other empty holes
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The shinny oil with bits of broken up bolts


side note I found what looks like some dating inside it. Wondering if that could be manufacturing date or not.
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It say 10 12 66. Could that be it was made in 1966? I don't have a vin or the original reg.
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Old 03-09-2017, 12:28 PM   #2
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Default Re: Scout 800 Rear axle surprise

Wow! That's a horrible surprise. Someone must not have torqued those bolts properly. Or, there was some catastrophic shock load induced that sheared damn near all of them at once. Hard to imagine from a 4-pooper engine. I wouldn't just throw new bolts in and slap it back together. I'm no axle expert, but I'd say that entire assembly including all bearings needs to be carefully inspected. A full blown rebuild May be in order. We'll see what some others have to say about that.

The only number that I know the meaning of for sure on that ring gear is the 47-11. Its a math equation. Divide the larger number by the smaller number and you get your axle ratio of 4.27 to 1, which is typical of 4-cylinder powered Scout.

There should be a bill of materials bom stamped into the axle tube, but it will be covered in layers of grime, rust and paint. Plus, the stamping is pretty shallow. Some strategic wire brushing May reveal the axle bom, which would include a build date. But unless you know for a fact that the axles are original to the vehicle, their build date May not be all that helpful to your quest.
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Old 03-09-2017, 09:46 PM   #3
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Default Re: Scout 800 Rear axle surprise

The good news is that you've got the better power-lock limited slip in there. Looks like it will need a complete rebuild though.
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Old 03-10-2017, 04:53 AM   #4
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Default Re: Scout 800 Rear axle surprise

I'm definitely glad I found it before all the bolts let go.
Side note there's a while at the top of the pumpkin, where I can only imagine a bolt flew out. I'll try and get a pic of the hole tonight.

Does anyone have a diagram or know the best way to dig into this baby? I'm trying to get my hands on a service manual but the ones I've found are like 70-80 bucks for what looks to be a black and white photocopied one.


I've been looking for the bom but haven't found it yet. Can it be seen from the outside of the truck? I've been looking under since I have it jacked up right now. I've seen a picture of what it looks like but all the ones I've seen have been to close to see where they are. I'm also thinking that the plow that's in it might be covering up the spot in the frame.

Also just heard we're getting a nor-easta coming through next week. Suppose to get another foot of snow. Great time to have 3/4 of the tires off my plow truck with the rear axle open. Haha. Might have to strap it all back together with some spit and duct tape for a few days.
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Old 03-11-2017, 08:18 AM   #5
jeff campbell
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Default Re: Scout 800 Rear axle surprise

Best thing you can do is just replace the rear end,to be ready for that 1' of snow.?
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Old 03-11-2017, 09:51 AM   #6
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Default Re: Scout 800 Rear axle surprise

Link to authorized reprint of bound fsm:

http://www.IHPartsAmerica.com/store/slcts-2302.html

It helps to make positive id of your axle model. It should be a tapered Dana 44. You can tell by the shape of the inspection cover and the number of bolts. Compare yours to pictures online of Dana 44 and Dana 27 covers. There are numerous write-ups and youtube vids detailing d44 rebuild steps. Most of them will be concerning the later, flanged design. There are differences between tapered like you should have and flanged d44. I've not done much inside a differential beyond installing a lunch box locker into an open carrier. That's peanuts compared to setting up an axle with new bearings, getting the pre-loads, end play and gear lash correct. There's a reason why shops charge big bucks for a full on axle job. Its a fairly involved procedure that requires some specialized tools and a good grasp of what you're doing.
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Old 03-29-2017, 04:19 AM   #7
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Default Re: Scout 800 Rear axle surprise

Alright.

So I was able to get four new bolts into the diff.

8 holes total. Two of which the bolt had sheered off after where the two pieces came together and two broke just before.

With 50% of the screws in I don't feel the most comfortable but ya better then just one bolt I suppose. Guess I won't be towing anything in this ol girl but that's okay.

I also welded a patch over the whole in the diff. Hopefully sealing it in nicely.

Got a new gasket from the local auto parts store and filled it with some 75w90.
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