Front D44 refresh

[Tahoedonner]

1979 Scout 2 d44 front axle, 3.73

I have purchased the following from IH only and will be replacing:
spindle service kit
wheel bearing kit
ball joints
axle u-joints
warn locking hubs

also bought new rotors, calipers, and pads.

I have gotten everything apart just fine and, of course, I have found a bit of rust inside the axle tubes.

What is the best way to clean the rust out of the inside of these tubes? How do I keep from contaminating the inner axle seals and bearings?

I am assuming that I can just wire brush off the rust on the axle shafts.

Finally, any hints and tips to the re-assembly of all the purchased parts above would be appreciated. I have read most posts and have all the proper tools but people always seem to have great first hand tips.



Drivers side tube

Drivers side shaft

http://forums.IHPartsAmerica.com/attachment.php?attachmentid=15634&stc=1&d=1330576062

Drivers internal spline

Passenger side axle tube

Passenger internal spline

Passenger axle shaft

 

[ihpartsjeff]

You'll probably want to pull out the carrier and remove the inner seals to best clean out the tubes. Once the carrier and seals are removed we use a large rod with some rags soaked in cleaner(we use brake cleaner) and balled up on the end and shove it through the tube. Spraying the inside of the tube ahead of time with cleaner helps as well. All the gunk will fall into the differential area where it can be further cleaned out. Looking at your tubes they really don't look all that bad and you May want to leave them alone if you don't want to go to all the trouble. If you do decide to do all this you will need new inner axle seals since the old ones get ruined and are usually of need of replacing anyway.

As for other tips I'm sure there are some but really following the service manuals instructions should allow you to do this repair as long as you have the correct tools.

 

[Tahoedonner]

Thanks Jeff. With your advice I think I will just clean off the axle shafts and seal it all back up. Inner seals look really good so I would rather not mess with them at this time. At some point I May drop in a locker up front and would replace them at that time.