Dana 44 set-up bearings...

[FINOCJ]

Just to ask, anyone have some D44 set-up bearings? Like these: https://eastcoastgearsupply.com/i-126960-dana-44-bearing-set-up-kit.html
I am hoping this is a one-time only job so looking to avoid buying these...

[Jim]

So they're machined slightly "out of spec" to allow them to be easily slid on/off, yes? You're replacing your old bearings, yes? Could you sand paper / grinding wheel in any fashion to modify the old bearings for the task?

[FINOCJ]

Correct - the pinon race and carrier bearings are 'press-fit' so they don't slide on and off easily - puller or press required to remove and damage can occur so its nice get it right before finalizing with the press fit bearings. The 'set-up' ones slide on and off by hand so you can easily change and test the spacers that go behind and get it right before finalizing with the press-fit ones. I was thinking of getting my old bearings machined out (its the inner diameter)...but when I pulled them, I may have damaged them too much. These tolerances are measured to the 0.001", so I am a bit leary. I only damaged (slightly) the outer cages - but still, when that is fitted into the race...not sure how much it will affect the fit? The old pinon race is fine so it could definitely be used - and its the outer diameter that I would need reduce.
Thinking about how I would bore out the inner diameter - not sure if sand paper would work...think I would need to take off more than that. And its absolutely critical that the inner diameter stay perfectly centered as it is opened up. I was thinking of getting a cylinder honing tool and putting it in the drill press and running it down through the bearing?