Dana 30 4.88's

[Wrench]

So, who has the strongest gears?

Yes it is confirmed:


These were Motive Gears. Not sure if it was a gear quality issue, or just an airborn Cherokee on a locked Dana 30 problem.

[mattawajeep]

Did an axle break as well? That's what I would expect to go first.

[TJDave]

Motive Gear 4.88 is living in my D30.

[Wrench]

Did an axle break as well? That's what I would expect to go first.

No. Nothing else is broken, and I am still using those early axles with the smaller u-joints...

[Wrench]

Taking a close look at the teeth breakage, it appears most of them were sheared as if I were loading it in reverse. My guess? I let off the throttle too much in the air, wheel spin slowed too much in the air, and the shock of both front wheels hitting the ground first popped a few teeth off.

...the drawbacks of a lightened flywheel?

Darn you, Norm. "Lets see who can get good air off that dune and break something...".

[iaccocca]

I let off the throttle too much in the air, wheel spin slowed too much in the air,

This is close to my new favorite quote.

Where as I am sorry for your breakage, I am shocked that it didn't happen sooner seeing how you wheel the pee pee out of that thing in the dunes. But, I have always been impressed with it.

Funny thing, one of the few pieces of wheeling advice my dad gave me was don't throttle down in the air, and my dad wheels / wheeled milder than me (yeah, it is possible, who knew.)

[79chevy39.5's]

i believe it to be related to the fact of "im flying through the air right now....not good" not the ring gear just failed

[Lurch]

I believe it to be that it is a d30. They just don't hold up to that kind of abuse well.

[Wrench]

OK, so do you think one of those nice diff covers would have helped?

The RuffStuff ones are pretty impressive!

If they could use some kind of "torque stick" technology built into axle shafts, that sure would alleviate a lot of problems.

[79chevy39.5's]

i believe the term is comp cutting it essential takes the shaft down some to let them flex, you may have some deflection in the housing maybe a truss (if you dont have one already and a thick cover with tight fitting bolts may help


may read up in this thread i know its dana 60 but the same should apply to any axle
http://www.pirate4x4.com/forum/chevy/96 ... ad-21.html

[White trash]

It's a 7 1/2" ring gear just how much did you think it'd take before spitting out teeth?

[OldGreen]

It's a 7 1/2" ring gear just how much did you think it'd take before spitting out teeth?

Should have happened WAY before it did. That was a tough little trooper!!!

[White trash]

It's a 7 1/2" ring gear just how much did you think it'd take before spitting out teeth?

Should have happened WAY before it did. That was a tough little trooper!!!

That's just it, with the history of abuse why is there any surprise that it failed?

[Wrench]

Based on the responses it seems there are only a few options:

1)be A LOT easier on it
2)go back down in tire size
3)go with a stouter axle
4) put this running gear in a rig 1000 lbs lighter
5)go back to riding motorcycles instead

[Livin4Today]

I'm still waiting for pictures... No xj flying, and your story doesn't jive...

But think option 3 would suffice... Although I do know of a 2002 HD Road King for sale on the cheap $8k w/a 95" motor.

Just sayin'...

[TJDave]

FWIW, I have personally seen Paul's wagon fly.

[Wrench]

I'm still waiting for pictures... No xj flying, and your story doesn't jive...

?

The guys I prefer to run with are usually too busy running around in their rigs to get pics. I prefer to live first-person rather than live vicariously through pics anyway...

I don't know how it broke, I was only guessing based on the angle the teeth sheared off. I never hear any pops or snaps, just ran around in circles up and down several dunes and noticed the clunking when I slowed a bit. I do know that I caught a few feet of air several times on one dune and landed pretty hard on the front.

Based on the pics, it is possible I did not have the gears set perfect. I believe the majority of the damage is on the outer edge of the teeth, so the pinion depth may have been off a hair. Also, (as I understand it) the high pinion fronts would theoretically be weakest on decel (or reverse). Who knows. But I would like to find something that has been proven to add a little more strength in this area.

[iaccocca]

Oh, it flies!



And that was a big a$$ dune.

[Wrench]

Anyone have a housing spreader I can borrow?

[Roman]

Housing spreader? That's why God created 2 goose neck pry bars . . .

[Roman]

Paul, my 2cents... Waggy D44 housing. Been telling Lee to do it in his for a LONG time now

[Wrench]

Paul, my 2cents... Waggy D44 housing. Been telling Lee to do it in his for a LONG time now

There will be a place and time for major upgrades, but not on this rig and not at this time.

I ordered a new set of gears and will just be a little easier on her until I move to something better.

So, no one has a spreader?

[Lurch]

I've never needed a spreader to get the carrier in or out. Just a little extra leverage from a pry bar or dead blow

[79chevy39.5's]

i always put a rag between the ring and pinion rotate using ratchet on pinion nut and pops the carrier out

as for building axles i would start with ford hp to try to get as much room as possible before the center section with the waggys (my research has been on pass drop ones) the center section is closer to the knuckle and makes it easier to get into the leaf/control arm with the tires

[Wrench]

Thanks, Graham, as you can see in the pic I already have it out.

I am looking to increase durability and was thinking that my previous dead-blow and prybar method of inserting the carrier left me with too little preload on the bearings. Lack of preload would equal carrier movement, which could compromise durability.

I also found this: on the drivers side carrier bearing, the bearing slid right off the carrier by hand. That's just not right, is it? If I remember right, I heated these bearings to drop them into place.

I think there were a number of small items that led to too much movement and misalignment of the teeth, causing them to break.