AMC Eagle Den Forum

The Shop => Axle / Differential => Topic started by: The Dark Side of Will on April 23, 2014, 09:10:55 AM

Title: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 23, 2014, 09:10:55 AM
In this thread: http://forums.amceaglesden.com/index.php?topic=22813.0
I discuss a built Eagle driveline consisting of a 4.0, stock flywheel and clutch, NV3550, NP229, non-c-clip D44 3.54 rear and and D30 Disco 3.54 front from a 4 cylinder Eagle.

I finally popped the cover off the diff... looks like it had some water in it. I'm not sure how that happened, as it's been sealed the entire time I've had it.
(https://lh5.googleusercontent.com/-CitKXff6AIc/UlbIrzNPT9I/AAAAAAAABTY/6AE_iGe_zkw/s800/100_2317.JPG)

Does anyone sell an overhaul kit for this diff? Is there an overhaul manual anywhere? I'd like to replace all the bearings and seals. The gears may be salvageable via electrolytic rust removal (e.g. http://realfierotech.com/phpBB/viewtopic.php?f=3&t=17528&p=142402 ).

Also, I understand that there are carrier differences between the D30 IFS and D30 axle related to pinion offset... is this correct? Where can I learn more?

EDIT: Interesting interchange info: http://forums.amceaglesden.com/index.php?topic=21608.msg207217#msg207217
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: carnuck on April 23, 2014, 04:12:57 PM
Pinion length changed between 80 and '82 somewhere I think. This is why you should drain and fill all diffs when you get a car. Especially 4x4. If water gets near the breather and the diff is hot, the sudden cooling draws it in through the breather.

The early non-vacuum diff has a 1.5" longer hanger on the passenger's side. The later non-vac ones are same as the vacuum ones.

As for kit, check http://ringpinion.com

If I weren't broke right now, I'd take my diff over there so I could get all those parts for mine.

I have the 2.72 front diff from my '82 on the for sale pile.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: vangremlin on April 24, 2014, 12:22:35 AM
Is there an overhaul manual anywhere?

There is a pretty good write up in the TSM.  Have you looked there?  Good luck!
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 24, 2014, 01:08:40 PM
Pinion length changed between 80 and '82 somewhere I think. This is why you should drain and fill all diffs when you get a car. Especially 4x4. If water gets near the breather and the diff is hot, the sudden cooling draws it in through the breather.

The early non-vacuum diff has a 1.5" longer hanger on the passenger's side. The later non-vac ones are same as the vacuum ones.

As for kit, check http://ringpinion.com

If I weren't broke right now, I'd take my diff over there so I could get all those parts for mine.

I have the 2.72 front diff from my '82 on the for sale pile.

Thanks!

Is there an overhaul manual anywhere?

There is a pretty good write up in the TSM.  Have you looked there?  Good luck!

This?

http://amceaglesden.com/guide/index.php?title=1982_%26_1983_TSM
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: Mernsy on April 27, 2014, 11:06:10 AM
Here's a bit of info.

http://amceaglesden.com/guide/index.php?title=Rear_Axle/Differential_R%26R
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on August 31, 2014, 11:18:40 PM
Ok... so here's section 9 of the parts book:
http://amceaglesden.com/guide/index.php?title=Group_9_Axles_--_Propeller_Shafts

Here's the Disco parts diagram:
(http://amceaglesden.com/guide/images/5/50/9axles004.jpg)

I made a .xls of the parts by group and part number, but I can't attach it to the post...

Code: [Select]
Group Part Number Nomenclature Amplification Description QTY
9.301-1 324 0159 4WD - With Part Time Axle (WPTA) 1981 FOUR 3.54 (13:46)
PO 9.303-1 Differential carrier bearing cap 2
PO 9.303-1 813 3625 HOUSING, Front Axle (Incl. Tube) 81 30-50 (WPTA)
813 4323 HOUSING, Front Axle (Incl. Tube) 82/83 30-50 (WPTA-* 9-2)
HOUSING, Front Axle (Incl. Tube) 83/ 30-50 (WPTA-* 9-3)

PO 9.368-1a 813 3610 SHAFT, Front Axle Drive 81/ (Inner-Right) 30-50 (WPTA) (Incl. Shaft, Cover, Seal, Bearing, Gear, Snap Ring, Screws) Right output flange 1
9.303-2 813 3608 ATTACHING PARTS, Axle Tube Cover 81/ 30-50 (WPTA) Right bearing plate bolt 4
9.368-2 813 3607 BEARING, Front Axle 81/ (Right Hand) 30-50 (WPTA) (Outer Bearing) Intermediate shaft bearing 1
813 4759 BEARING, Front Axle 81/ (Right Hand) 30-50 (WPTA) (Inner Needle Bearing) Intermediate shaft bearing
9.368-1 813 3606 SHAFT, Intermediate Front Axle Drive 81/ 30-50 (WPTA) (Incl. Needle Bearings and Snap Ring) Intermediate shaft 1

PO 9.368-1a 813 0752 SHAFT, Front Axle Drive 80/83 (Inner-Left) 30-50 (* 9-2) Left output flange
813 4585 SHAFT, Front Axle Drive 83/ (Inner-Left) 30-50 (WPTA * 9-3) Left output flange
9.368-2 813 2821 BEARING, Front Axle 80/83 (Left Hand) 30-50 (* 9-2) Left output flange bearing
813 4586 BEARING, Front Axle 83/ (Left Hand) 30-50 (WPTA * 9-3) Left output flange bearing
9.368-3 813 0762 SEAL, Front Axle Oil 80/83 (Left Hand) 30-50 (* 9-2) Left axle seal
813 4587 SEAL, Front Axle Oil 83/ (Left Hand) 30-50 (WPTA * 9-3) Left axle seal
9.368-6 813 0763 RING, Inner Axle Shaft Snap 80/ 30-50 C-clip 2

9.410-1 813 3609 COLLAR, Axle Shift 81/ 30-50 (WPTA) Disconnect shift collar 1
9.410-2 813 3617 FORK, Axle Shift 81/ 30-50 (WPTA) (Incl. Snap Ring, "O" Ring, Insert Kit) Disconnect shift fork 1
9.410-3 813 3618 SNAP RING, Shift Fork 81/ 30-50 (WPTA) Disconnect shift fork to actuator shaft snap ring 2
9.410-4 813 3708 INSERT KIT, Shift Fork (Incl. Inserts, Gasket, Screw, Lockwasher) 81/ 30-50 (WPTA) Shift fork friction inserts (?) 1
9.414-1 813 3616 COVER, Axle Shifter Housing 81/ 30-50 (WPTA) Disconnect cover
9.414-2 813 3624 ATTACHING PARTS, Shifter Cover WASHER 81/ 30-50 (WPTA) Disconnect cover washer
9.414-2 813 3623 ATTACHING PARTS, Shifter Cover BOLT 81/ 30-50 (WPTA) Disconnect cover bolt
9.414-3 813 3709 GASKET, Shifter Housing Cover 81/ 30-50 (WPTA) Disconnect cover gasket
9.415-1 813 3621 MOTOR, Axle Shifter Vacuum 81/ 30-50 (WPTA) (Incl. "O" Ring, 2 Snap Rings, Insert Kit) Disconnect actuator
9.415-2 813 3620 "O" RING, Motor to Housing 81/ 30-50 (WPTA) Disconnect actuator body o-ring
9.415-3 813 3619 SNAP RING, Vacuum Motor 81/ 30-50 (WPTA) Disconnect actuator body retaining snap ring
9.415-4 324 0501 SEAL, Vacuum Motor Drain 81/ 30-50 (WPTA) Drain fitting dust cap

9.341-1 812 6500 BEARING, Front Axle Differential Side 80/ 30-50 (Incl. 2 Cones and 2 Cups) Differential carrier bearing set 2
9.345-1 813 0760 SHIM SET, Front Axle Differential Side Gear Bearing 80/ 30-50 Differential carrier bearing shim set
9.318-1 G179890 SCREW, Bearing Cap 80/ 30-50 Differential carrier bearing cap bolt 4
PO 9.321-1 813 3720 CASE ASSEMBLY, Front Axle Differential 81 30-50 (WPTA) Differential carrier
813 3720 CASE ASSEMBLY, Front Axle Differential 82/83 30-50 (WPTA 20:47 Ratio) Differential carrier
813 4324 CASE ASSEMBLY, Front Axle Differential 82/83 30-50 (WPTA Except 20:47 Ratio) Differential carrier
9.336-2 636 360 PIN, Front Axle Differential Shaft 80/ Differential cross pin retaining bolt
9.336-1 812 0833 SHAFT, Differential Pinion Mate 80/ 30-50 Differential cross pin
9.333-1 812 0831 WASHER, Differential Pinion Gear Thrust 80/ 30-50 Spider gear thrust washer 2
9.327-1 813 3721 GEAR SET, Front Axle Differential Side And Pinion 81/ 30-50 (WPTA) Side & spider gear set 2
9.329-1 813 3724 WASHER, Differential Side Gear Thrust 81/ 30-50 (WPTA) Side gear thrust washer 2
PO 9.307-1 812 6498 COVER, Front Axle Housing (Incl. Plug) 80/30-50 Differential cover
9.307-2 991 546 ATTACHING PARTS, Cover to Housing SCREW 80/ 30-50 Differential cover bolt 10
9.305-1 G103869 PLUG, Axle Housing Fill 80/ 30-50 Fill plug
9.307-3 812 0360 GASKET, Front Axle Housing Cover 80/ 30-50 Differential cover gasket

9.350-2 649 454 ATTACHING PARTS, Ring Gear to Differential Case BOLT 80/ 30-50 Ring gear bolt 10
9.350-1 813 2831 GEAR SET, Front Axle (Incl. Pinion, Shims, Bearings, Seal, Slinger & Baffle) 80/ 30-50 3.54 (13:46) (Use 812 6518) Ring & Pinion
PO 9.355-3 812 6499 BEARING KIT, Front Axle Pinion Inner (Incl. 1 Cone and 1 Cup) Pinion rear bearing cup & cone
PO 9.355-4 812 4052 BEARING KIT, Front Axle Pinion Outer (Incl. 1 Cone and 1 Cup) 80/ 30-50 Pinion forward bearing cup & cone
9.357-1 813 0759 SHIM SET, Front Axle Differential and Pinion 80/ 30-50 Differential carrier & pinion bearing shims
9.364-4 934 937 BAFFLE, Pinion Bearing Oil 80/ 30-50 Pinion bearing oil baffle
9.364-3 916 372 SLINGER, Pinion Bearing Oil 80/ (Inner) 30-50 Pinion bearing oil slinger
636 566 SLINGER, Pinion Bearing Oil 80/ (Outer) 30-50 Pinion seal oil slinger
9.364-1 998 092 SEAL, Front Axle Pinion Bearing Oil 80/ 30-50 Pinion seal
9.404-1 813 3525 YOKE, Front Axle to Propeller Shaft 81/83 30-50 (Four) Input yoke
813 3241 YOKE, Front Axle to Propeller Shaft 80/ 30-50 (Six) Input yoke
9.350-5 636 570 WASHER, Pinion Nut 80/ 30-50 Washer (keyed?)
9.350-4 801 367 NUT, Pinion 80/ 30-50 Pinion nut
9.350-6 813 0758 SHIM SET, Front Axle Pinion 80/ 30-50 Pinion bearing shim set

Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on August 31, 2014, 11:28:51 PM
Is there an overhaul manual anywhere?

There is a pretty good write up in the TSM.  Have you looked there?  Good luck!

This?

http://amceaglesden.com/guide/index.php?title=1982_%26_1983_TSM

Section 2F of the TSM is the one that covers the axles, and it is not available on the wiki.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on September 01, 2014, 11:56:44 AM
Pinion length changed between 80 and '82 somewhere I think. This is why you should drain and fill all diffs when you get a car. Especially 4x4. If water gets near the breather and the diff is hot, the sudden cooling draws it in through the breather.

The early non-vacuum diff has a 1.5" longer hanger on the passenger's side. The later non-vac ones are same as the vacuum ones.

As for kit, check http://ringpinion.com

If I weren't broke right now, I'd take my diff over there so I could get all those parts for mine.

I have the 2.72 front diff from my '82 on the for sale pile.

How do I tell which pinion length I have?

There doesn't seem to be much in the way of overhaul info or parts for the disconnect mechanism (IE, all the little bearings and junk associated with it).

Next step is to knock the diff apart and see what actually needs replacement.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: carnuck on September 01, 2014, 05:21:50 PM
With the axle out or at least hanging down enough you can use large measuring calipers to measure from the center divot of the front to the middle of the gear face.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on September 02, 2014, 08:43:15 PM
With the axle out or at least hanging down enough you can use large measuring calipers to measure from the center divot of the front to the middle of the gear face.

Not visualizing what you're talking about.
Do you mean "pinion offset" instead of "pinion length"?
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on September 02, 2014, 09:01:31 PM
If I filter these tables for 3.54 Disco:

Quote from: FredCDobbs
(http://i34.photobucket.com/albums/d125/phredcdobbs/Eagle235001.jpg?t=1254034266)
(http://i34.photobucket.com/albums/d125/phredcdobbs/Eagle235002.jpg?t=1254034426)


I get this table

Code: [Select]
Disco 3.54

Year BOM R&P Case Assy Case Left OP
1981 610134-5 700128-6 706819X 700130 620516
82-82.5 610153-5 706819X 700130 620516
83-84 610174-5 706830X 706831X 620842

I don't know what year car my diff came from.
Is the part number anywhere on the carrier ("case" per AMC) to let me figure out which one I have?
All the 3.54 apps use the same R&P, though. Since I'm starting with a 3.54 diff and (probably) replacing 3.54 gears, I shouldn't have any problems. It's only when swapping out for 2.35's that people have problems, AIUI.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: carnuck on September 05, 2014, 12:27:14 AM
So maybe it's just when swapping to different year cases that it doesn't work? As for the measurement.

http://www.greenfries.info/images/Rear_gear/DSC04741.JPG

http://www.macysgarage.com/myweb6/images/DCP_3242s.JPG

http://www.macysgarage.com/myweb6/diff-overhaul.htm

(even though it's Brit bits, the theory is the same)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on October 19, 2014, 08:20:09 PM
My dad and I did a bunch of disassembly on the diff unit today...

The pinion and/or diff bearings are so cruddy that I had to use a pretty big lever to turn the unit to the point that I could get the C-clips out of the diff.

Once the left C-clip is out, the left output flange pulls right out, leaving its seal and bearing in the case. We haven't gotten those out yet.

The disco cover unbolts and the disco shift fork comes out with it.

The seal retaining plate under the right output flange comes out with 4 socket cap screws. There's an access hole in the flange that allows a tool onto the fasteners. We had to put a couple of bolts into the flange and use a slider hammer to get it out, but it comes out with the retaining plate, seal, bearing and disconnect "gear". The gear is a light press onto the splines and ALSO retained with a snap ring. The cone is a light press onto the shaft.

Once the right output flange is out and the right C-clip is removed, the intermediate shaft slides right out. There's a small roller bearing just inboard of the disco box that supports the right end of the intermediate shaft. We have not removed this yet. The TSM calls out J26225 to remove this bearing. This tool is also used on T5 transmissions and is readily available on ebay.

We pulled the diff carrier bearing caps and found the cup numbers shown below, but we don't have the case spreader tool required to get the carrier out, so we stopped there. The tool is a 24385-01, which has many applications and is available on ebay from $120ish.

We may be able to use a slide hammer to get the left bearing & seal out, but will most likely be able to knock them out more easily with a punch once the carrier is removed.

Here are the part numbers we liberated today:
LM501314   Cup - Diff carrier bearings

U261L      Cup - Right flange bearing
U298      Cone - Right flange bearing
35938-1      Seal - Right flange

543290      Seal - Left Flange

J26225      Intermediate shaft roller bearing removal tool
J24385-01   Case spreader set

Title: Re: Overhauling Disco front diff: Parts list or references
Post by: eaglebeek on October 20, 2014, 11:13:05 AM


We pulled the diff carrier bearing caps and found the cup numbers shown below, but we don't have the case spreader tool required to get the carrier out, so we stopped there. The tool is a 24385-01, which has many applications and is available on ebay from $120ish.



I rented a carrier spreader last time I needed one. Perhaps there's a shop in your locale where you can do likewise. :eagle:
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on October 20, 2014, 05:43:10 PM
My dad knows a couple of guys around... we'll talk to them this week.

I can ask at CarQuest or similar if they have one... but I doubt it.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on November 06, 2014, 01:23:23 PM
A friend of my dad's uses a pair of pry-bars to get the carrier out when he overhauls Dana stuff... never had or used a case spreader.

Here's some actionable information:

Code: [Select]
Description                        AMC PN  Part Mark    Industry        Dimensions         Carquest
Left output flange seal            8134587 543290       National 470950 1.375 ID, 2.440 OD $13.00
Left output flange bearing         8134586 6007         6007 (107?)                        $41.00
Intermediate shaft needle bearing  8144759 BH208        BH208           1.250 ID, 1.625 OD $16.60
IMS to Right output needle brg     8134759 B168         B168            1" ID, 1.248 OD    $16.59
Right output flange bearing        8133607 U261L & U298 A9 set          1.378 ID           $37.17
Right output flange seal           8130762 35938-1      National 2146   1.688 ID           $13.49

Because it has different seals left and right, it looks like my axle is an '83+

Still to come: diff carrier bearings & pinion bearings. Those should be easier as they are standard Dana 30 overhaul parts.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 15, 2014, 11:16:37 AM
The dual prybar method worked easily... no case spreader required.

Code: [Select]
Description                        AMC PN  Part Mark    Industry        Dimensions         Carquest
Left output flange seal            8134587 543290       National 470950 1.375 ID, 2.440 OD $13.00
Left output flange bearing         8134586 6007         6007 (107?)                        $41.00
Intermediate shaft needle bearing  8144759 BH208        BH208           1.250 ID, 1.625 OD $16.60
IMS to Right output needle brg     8134759 B168         B168            1" ID, 1.248 OD    $16.59
Right output flange bearing        8133607 U261L & U298 A9 set          1.378 ID           $37.17
Right output flange seal           8130762 35938-1      National 2146   1.688 ID           $13.49

Inner pinion bearing cup           8126499 HM88610                                         $ 9.25
Inner pinion bearing cone          8126499 HM88649                                         $19.57
Outer pinion bearing cup           8124052 02820                                           $9.56
Outer pinion bearing cone          8124052 02872                                           $26.13
Differential carrier bearing cup   8126500 LM501314     Set A35                            $19.17 (set)
Differential carrier bearing cone  8126500 LM501349     Set A35                            $19.17 (set)
Pinion Seal                        998092               5778            1.552 ID, 3.16 OD  $15.06

The pinion slinger got a little mangled during removal of the pinion bearings.
I didn't see a part mark on the pinion seal and it was extremely mangled during removal anyway.

Now the housing is completely empty except for the intermediate shaft roller bearing mentioned above.

The side gear splines (left output flange and intermediate shaft) are 1.160 x 27 spline
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 15, 2014, 11:43:12 AM
Here's the inside of the housing... haven't cleaned it yet and it's pretty nasty.

(http://lh5.googleusercontent.com/-yQhxI9icWAA/VI8Op93GDPI/AAAAAAAADOA/X2YPP9JonlU/s800/IMG_0030.JPG)


The inside of the disco housing and the intermediate shaft roller bearing

(http://lh5.googleusercontent.com/-Aa-tUb1vZ5Y/VI8Okj_DwAI/AAAAAAAADN0/OlnK8lNcag4/s800/IMG_0032.JPG)


The typical condition of bearings in this unit

(https://lh5.googleusercontent.com/-yntiHlwsNkM/VI8OqTlU6oI/AAAAAAAADOE/LIz-M9ovrm0/s800/IMG_0035.JPG)


The pinion isn't in bad condition except for the teeth

(https://lh6.googleusercontent.com/-YDeKg5RyR6Y/VI8OwyPLIlI/AAAAAAAADOM/loxR8uQlnKo/s800/IMG_0037.JPG)


The NP 229 output yoke and the Dana 30 input yoke... you guess which is which ;)

(https://lh6.googleusercontent.com/-sHU7wKw_YhI/VI8Ozy9b-qI/AAAAAAAADOU/m9k50rTNWnU/s800/IMG_0038.JPG)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: eaglefreek on December 15, 2014, 12:34:16 PM
Wow, that's pretty nasty in there.  :o
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 15, 2014, 01:13:57 PM
Yeah, it's pretty vile.

I will *probably* try electrolytic rust removal first on the carrier assembly and the pinion... That's the lightest touch rust removal there is.

Also need to clean the disco box out and measure the installation depth of the intermediate shaft roller before figuring out how to knock it out of there.

The disco parts are in pretty good shape, except for the right output flange bearing. If the gears clean up, this unit should go back together pretty well.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: carnuck on December 15, 2014, 01:25:28 PM
D30 on left but I think the D35 yoke may be the same as the tcase
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 15, 2014, 02:31:56 PM
I was really just amused by the huge difference in the spline sizes for the same U-joint. The NP 229 was used with 360 V8's and Wagoneers with D44's, so it's a tough unit.

I haven't seen a D35 that's an easy swap for the stock D30. The Ranger unit is interesting, but has the mount carriers cast in, so it's hard to adapt it to the Eagle mounting method.

I have the Eagle shock brackets welded onto my D44... I'll blast, paint & prep it (disk brakes!) once I get the front end taken care of.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: carnuck on December 15, 2014, 08:09:43 PM
I meant the D35/M15 yoke to the NPxxx cases.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 21, 2014, 05:05:30 PM
Diff carrier bearings are off... Had to clip the cages and pull them off first to have good purchase on the inner races with a puller. I added the number to the list above. We segregated the shims... if the gears are salvageable, then we should just be able to slap it back together with the same shims and not have any problems.

We're going to clean the carrier assembly and pinion up in the parts washer, then try electrolytic rust removal first.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on January 24, 2015, 11:03:10 PM
Per my thread here: http://realfierotech.com/phpBB/viewtopic.php?f=3&t=17528&p=142402

I set up an electrolysis cell to remove rust from the pinion.
It worked... the pinion is nice and clean.
However, there is definite surface damage in the valleys between teeth. It doesn't extend out to the tips of the teeth.
I'm going to take it to a friend of my dad's who runs a transmission and axle shop... maybe he'll have a better feeling for whether or not (or maybe just how much) noise it would make if we put it back together with these gears vice getting new gears.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 25, 2015, 07:49:15 PM
From this:

Quote from: The Dark Side of Will
The pinion isn't in bad condition except for the teeth

(https://lh6.googleusercontent.com/-YDeKg5RyR6Y/VI8OwyPLIlI/AAAAAAAADOM/loxR8uQlnKo/s800/IMG_0037.JPG)


To this:

(http://lh3.googleusercontent.com/-Noup-BnpTXQ/VTwEllTCZbI/AAAAAAAAD54/GPkcKWQKc7s/s800/20150425_165451.jpg)

via electrolytic rust removal.

From this:

Here's the inside of the housing... haven't cleaned it yet and it's pretty nasty.

(http://lh5.googleusercontent.com/-yQhxI9icWAA/VI8Op93GDPI/AAAAAAAADOA/X2YPP9JonlU/s800/IMG_0030.JPG)



To this:

(http://lh3.googleusercontent.com/-6qajOXFurPQ/VTwldB0iqWI/AAAAAAAAD6s/XrGJ_t-pL9Q/s800/20150425_192534.jpg)

Was just a matter of cleaning it up in the parts washer

Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 25, 2015, 07:54:17 PM
double post
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on July 12, 2015, 03:03:55 PM
Got the intermediate shaft roller bearing out.

(http://lh3.googleusercontent.com/-8s8T3CbcCfU/VaK4sU8XPSI/AAAAAAAAE6Q/6Hmn2drKORU/s800-Ic42/20150705_095155.jpg)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: carnuck on July 12, 2015, 07:51:17 PM
where is that bearing? On the stub or the output shaft?
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on July 12, 2015, 09:21:14 PM
It's BETWEEN the disco housing and the pumpkin. It carries the intermediate shaft that connects the right side gear to the disco mechanism. As such is also supports the right output shaft. The right output shaft only has one bearing in the disco housing, but also has a pilot into the end of the intermediate shaft.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: mo.eagles on July 19, 2015, 01:16:16 PM
Last winter one very cold morning ,Thing 2 did not want to move .Thought I had parked it with wet brakes and they had froze. After 15 minutes of warm up it drove to work with no problems the rest of winter . Last week the front diff started clanking and banging especially in rev. I did not take carnuck's advice and drain all of PO's fluids (and water) from diffs. So I'll be doing the same repairs as Dark Side. Good job with the pic's that will help .
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on September 07, 2015, 07:42:03 PM
The Timken kit from Yukon with a National bearing from CarQuest to hone out to a slip fit on the pinion and use for setup purposes.

(https://lh3.googleusercontent.com/-XAzaAV-6daw/Ve4VwXidlAI/AAAAAAAAFSA/WWPsQpdjxHc/s800-Ic42/20150907_102957.jpg)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on November 01, 2015, 08:46:25 AM
I found this page: http://www.4wheelparts.com/hardparts/HP_PartList.aspx?hpDID=51

With this diagram:

(http://www.4wheelparts.com/images/hard-parts/27-VintageHoliday08.jpg)

To be very helpful in selecting the right slingers or order, as I bent most of mine getting the pinion out and pinion bearings off.

Since DRP hasn't gotten their act together for producing the D30 threaded pinion bearing spacers, I will have to  order a shimmed one.

Does the Eagle D30 have a short pinion or long pinion?

Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on November 28, 2015, 09:03:25 PM
So I've been slow rolling this build and being concerned about other things *WAAAYYYY* too long. I ordered my new garage door 10 days ago with 3 weeks of lead time, so I'm out of other things to pretend I'm busy with.

I'm going to make my own solid pinion spacer, so here are the requirements:

Minimum ID: bare clearance on a 1.375" shaft.
Maximum OD: ~1.670
Minimum length: 2.310 less thickness of outer pinion bearing shims and slingers

EDIT: 1 1/4" sch 40 pipe has pretty much the exact dimensions I need. I snagged a 10" piece of it to use as a bearing press mandrel and then cut up for a bearing spacer. I cut it in a pipe cutter then faced the ends in a lathe.

Relevant dims:
Inner Pinion Bearing Cage ID: 1.772
Inner Pinion Bearing Cone OD small end: 1.670
Outer Pinion Bearing Cage ID: 1.900
Outer Pinion Bearing Cone OD small end: 1.780

Unfortunately I can't find the original crush sleeve from which to measure, which PTFO's me.

McMaster carries rounds shims with 1.250" ID and 1.750" OD (e.g. PN 3088A328 (http://www.mcmaster.com/#3088a328/=100k1cz) ). The ID of the shims can be smaller than the ID of the spacer because the shaft diameter tapers from 1.375" where the inner bearing cone presses on to 1.125" where the outer bearing cone presses on.

Inner Pinion bearing cone press mandrel:
Min ID: Bare clearance for 1.375" shaft
Max OD: ~1.770 (fit inside inner pinion bearing cage)

Inner pinion bearing cup press mandrel:
Max OD: 2.842
Min OD: 2.660
Shoulder max OD: 2.100
Shoulder min length: 0.780

Outer pinion bearing cup press mandrel:
Max OD: 2.872
Min OD: 2.643
Shoulder max OD: 2.236
Shoulder min length: 0.685

I won't need a press mandrel for the outer pinion bearing cone because once I have the shims for the solid bearing spacer set correctly using the honed out setup bearing, I just install the service bearing with the yoke and pinion nut.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 25, 2015, 07:10:25 PM
So appaaaaaaaaaaarently, I am an idiot.

The outer bearing seats against the shoulder on the pinion. No crush sleeve or bearing spacer required. I didn't remember there being a crush sleeve that came out, and I thought I had just misplaced it... but there never was one and I just wasn't paying attention when I took it apart. The slinger for the outer bearing is convex up in this photo

(https://lh3.googleusercontent.com/-I03L9cdWR-A/Vn3Yina3dpI/AAAAAAAAFu0/XpdG_KWn2X4/s800-Ic42/20151225_185700.jpg)

Also installed the cups in the housing. It turns out the old races make the best press mandrels. It wasn't clear prior to assembly that none of the cups go far enough into their bores that the old race would also be pressed in and difficult to remove.
The shims were 0.010 + 0.010.
The small baffle has the bulge *TOWARD* the camera in this shot (that's the only way it clears the inner bearing):

(https://lh3.googleusercontent.com/-0DsCzoTqp9w/Vn3Yp-yWpiI/AAAAAAAAFu8/5h5t77JEQ5I/s800-Ic42/20151225_184916.jpg)

The shims are between the baffle and the housing.
Here's the other side of the same shot:

(https://lh3.googleusercontent.com/-CZ1cmEQuZTs/Vn3YyuakL0I/AAAAAAAAFvE/DnMEdtp-DSU/s800-Ic42/20151225_184822.jpg)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: vangremlin on December 25, 2015, 07:34:44 PM
Thanks for the pics and good luck wrapping up this project.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 25, 2015, 09:37:40 PM
You're welcome! Glad to share.

Of course I forgot to bring my inch lbs torque wrench with me to my dad's house, so I won't be able to measure pinion preload this weekend. I'll put it together with a setup bearing and make sure the original shims are reasonable with the new bearings. I'll do the final installation probably next weekend.

After that, I need to reinstall the carrier and verify the pattern, then I can seal it back up and bolt it to the engine!
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 26, 2015, 07:57:39 PM
Honed the setup bearing today.

My dad had a brake cylinder hone, which is definitely the wrong tool for the job. I had him get new stones for it a couple of weeks ago.
I was able just barely to grab the bearing in the drill press vice and use the drill press to turn the brake cylinder hone. I cranked the tension in the hone up as far as it would go. We used a little bit of heating oil from his tank as cutting oil. It became surprisingly cloudy with swarf as we periodically rinsed off the hone in it. We flat wore out a brand new set of brake cylinder hone stones, BUT the setup bearing slips on and off the pinion shaft easily now.

(https://lh3.googleusercontent.com/-1EGU3b29MOY/Vn82Wlylh6I/AAAAAAAAFwc/RnJa2RUI_v0/s800-Ic42/20151226_123440.jpg)

(https://lh3.googleusercontent.com/-Vn9621dgr5U/Vn82eGZVAMI/AAAAAAAAFwk/j8KDgWExb4k/s800-Ic42/20151226_124057.jpg)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on January 01, 2016, 08:32:58 PM
First trial assembly netted 46 inch lbs of pinion preload... The spec is 12-15 with new bearings.  I guess I have to order a shim pack!

ETA: Realized I had installed a protective washer (or maybe just a thick shim) on the wrong side of the bearing. I rectified that error, but I'm still seeing 32 in-lbs!

ETA2: I ordered 3088A937 (http://www.mcmaster.com/nav/enter.asp?partnum=3088A937) from McMaster-Carr, which is an assortment of round steel shims with 1 1/8" ID and 1 5/8" OD.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on March 13, 2016, 06:47:29 PM
Went 0.007 above stock (0), sanity checked original shim pack (still 32), then .004 (~8), then .003(~11), then .0025 to finally got a reading between the 12.5 and 15 in lb graduations on my torque wrench. Some genius in China laid out the markings on the dial with three marks between 10's... so it doesn't have 12, 14, 16, 18 like an American would expect... it has 12.5, 15, 17.5.  %)

Anyway, pinion bearing preload is set. Next: carrier bearing preload and contact pattern. I sure hope the factory pinion depth setting is right, because fixing it requires removing the inner bearing cup from the housing (and probably mangling the inner bearing outer slinger) in order to reset pinion depth.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 04, 2016, 08:22:56 PM
Carrier is in place with the original shims, but I did not get the chance to check the pattern today.

(https://lh3.googleusercontent.com/-fYtYOTNxnOw/VwF5f7rulvI/AAAAAAAAGKE/zJKGFkXWtFYqrKA-0tP5y2p9_tLxCjONgCCo/s800-Ic42/20160403_160813.jpg)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 23, 2016, 02:40:16 PM
The bearing cap bolts are at 45 ftlbs. I found this thread asserting that 45 ftlbs is the FSM number: http://www.jeepsunlimited.com/forums/showthread.php?535132-Dana-30-Bearing-Cap-Torque-Spec

But also found this page saying that it should be 60 ftlbs: http://www.drivetrainshop.com/Dana_30_s/85.htm
My dad has an Eagle FSM... it says 57 ftlbs.

My dad's indicator set disappeared, so we had to borrow one in order to check backlash.
This set came out in spec at 0.010".

(https://lh3.googleusercontent.com/-9S3BKs2GNTA/Vxu08dXBRsI/AAAAAAAAGhE/_LbE5zOTXLAF5wM7y_1W2J_7gunuq0GjACCo/s800/20160423_133212.jpg)

We did the first pattern check... which was easy. I tried to take photos of the pattern to post on the internet... which was hard.

(https://lh3.googleusercontent.com/-DE82yOYuwGw/VxvJWgsjr-I/AAAAAAAAGiY/p4ipCemUsCsmnczSyeFDFHn2Ry4qPYgTQCCo/s800/20160423_151122.jpg)

(https://lh3.googleusercontent.com/-UPiz4wjjNJ4/VxvJQ-QUfRI/AAAAAAAAGiU/5zShTV5YqMwEIeqDMitTRnd2DJELlD27ACCo/s800/20160423_151146.jpg)

Here's Dana's own setup guide:
http://www2.dana.com/pdf/5717.PDF

And a quick read on NAXJA: http://www.naxja.org/forum/showthread.php?t=1064802

It looks like the pattern is a smidge toward the toe but not sure if there's a good enough strip of no contact just below the top land.
However, this is a set of original gears, installed at the original pinion depth in the case in which they were originally installed. The only components I changed are the bearings. It *should* go back together just fine with the original shims, yes? The inner pinion bearing and both carrier bearing shims are original. I changed the pinion outer bearing stack .002 as noted above in order to get the pinion preload right.

What do you guys think of the pattern? Need a better pic?
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on April 30, 2016, 03:56:51 PM
Hauled the diff up to a friend of my dad's who operates his own shop and has done a lot more drivetrain work than we have. Once we got him over the idea that the drive and coast sides were swapped compared to what he was used to, he liked the pattern and the preload, so we're proceeding to button it up. I swapped out the setup bearing for the "real" bearing, pulled it on with the yoke, then installed the pinion seal... then realized I'd forgotten the slinger, so had to carefully pry the pinion seal back out in order to install it. I used some of the anaerobic goo for sealing Getrag case halves on the OD of the pinion seal to reinstall it, since the factory application had been scraped off by the first installation.

The paper manual spec for the pinion nut is 210 ftlbs. The torque wrench only goes to 200, so that will have to do.
I pulled the bearing cap bolts to 60 ftlbs because the book specifies 57, but one of them felt a little weird. The originals are 7/16-14 x 2.25 with grade *5* markings on the heads. I ordered an ARP 645-2500 kit with five 7/16-14 x 2.5" bolts and washers. The holes are 2.578 deep, so a 2.5" bolt with washer should have almost 0.180 of extra depth left over. That should be plenty. If not, we can run a bottoming tap into each hole.

CarQuest quoted me almost $90 for the remaining three bearings and two seals. We'll see what another local supplier can do this week.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on May 08, 2016, 01:17:16 PM
Quote from: The Dark Side of Will
No reason I can't get the diff buttoned up next weekend

So... that was a really dumb thing to say. Of course there's going to be a reason.

The bearing on the left is the one that CQ had... the bearing on the right is the one that came out of the unit:

(https://lh3.googleusercontent.com/um8LFhZv1OPG5wYgH4zYjHACOFRaK_eiy0rSurCggiExKgzDl5IQbPZxpHlOCp8s2EsG-MLutjBrMM7FexvubkvATjjjV09RwsAEUeudwBVK6f7tnqZ6P_S2kPVU4ef6T6fu0fjXV0yYCAuZyfIJjoD0nS71ZMCopltE_3zKXFbu6CpmMRjgEuttRjjVXD0d1DuL_OjRsqUNd5h6mFSNnwsyhpzzaLHwLqVg1QOH9r4OLZMYKKRoZf95_tWOJ-ZrfT_Whl1HZiJxfobnv6XjzAQc9crmafiOoro8IB46GPWWN9vnN8HMnaNkwpKZ0GDT3bE_ZwXeifR5XX52Zl9_s-ZdK_pSh_TDwwWE4q_McvCTPCEqDAP62b3-WBIIPXyF2Nx-GI3Z3YFbkLCSTuiZeTRFsEfp3ezxNn73HALK4uFR1yxXXSM4RIP4JTWKSDO889vb6rMhbxs2-B9LUnHAolj06RfTLEjg4Y40kI-f72ckzREXfE6UmBKo4TzatRzLDCL7p14uCY3GzztmXnGZIVUs5jClJ9i83VCI0PuUoJJ-Y0VKsTxTvxYik2jeplObB27RYWD3HZPjAH1eA345dJENj_IYB9o=w501-h667-no)

Oooops. The AMC part number cross-references to a B168 bearing, which is what I had CQ order. The actual bearing is a BH208. I was a :censored: and let CQ order the one that crossed from the AMC part number rather than going by the part mark itself... I allowed myself to be victimized by a catalog error. CQ is getting the correct bearing in, but I won't be able to work on it until the 21st.

That bearing is the first part that has to be installed in order to assemble the disconnect mechanism and the right output flange... ok, I'm DIW for the right side.
Cleaned up the left side flange and discovered that it's heavily pitted on the seal journal. Oops sommore. CQ has a 1.375 speedy sleeve on the way, but I still won't be able to work on it until the 21st. At least I can repaint it before then.

(https://lh3.googleusercontent.com/-C5zs0BRKsQhSLkAhQX2pG3V2NkL8QJJOS1LkkQo80GuOhzRDjshcxLn_ntfwvPEiMRb6AhaEs2Xv61p7QP3k84ivjziCAG16Q6qjMcIheI7d341BGlNoUlVpEft3WlPe--T3SzY7D49V0NBPWrE2eiof8HIswa0BZO_b5k0dgFsFyEU9-tZrqXGhFC_WdrmPRAr-d7WLfzte7ksLZRDHKG-qpu0AcsQtL5Wr7V9TikUAW40LC1-lVq3uLE42G01TlbqOqDD-OoOOXltRJ9HsfMXbGPKuIDsPBWNuarZNLqEngCeTRWzsLEOC3SU7WUb2T4GHhwyikifqd9_r1nw-IGY2hpHB1yyp72PRzEGFf_WLCLYXg44LQhIQAh7IL7zxuJ4KPuo1E_BivhWVyYB9_hCWMxRAul_DS1HPSoWA-q3Ye3hFwSB0aoBnw8ld__e2n_WHUvj4WeA_dU1TFrzWU9Hk2ymWXYzQ2q9eTd7aKzqdZZp9ojXXIMM12hYKKTRLJdU6qP9ElCwiBkkFZw_NwwBcgxc3SRc7Hqgn3geVGGYr9k2NCE_DVitNGFBYYXvPqRdChKPUqSg-CXNlFePsWWgECL5QFg=w501-h667-no)

Yeah, I'm not being a great project manager with this assembly.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on May 21, 2016, 01:06:09 PM
Feh... another week of no progress.
My bearing and speedy sleeve sat around the CQ for a while. The CarQuest proprietor *sent the bearing back* to minimize inventory, even though it was paid for. Sigh. She missed the sleeve, so I have that. A 1.375" speedy sleeve is 27 freaking dollars... Holy cow, they're proud of that thing.


I cleaned up and painted the output flanges, at least. I still need to blast and paint the right flange bearing retainer.

At least the ARP bolts arrived; I installed those without incident. I had to work them in and out a few times to clean the threads, as they're ~0.250 longer than stock.

Output flanges:
(https://lh3.googleusercontent.com/0DggTtoEXkSHEb12YkEPMFJL1irD6jhjihCNa4KDC3Ef5LxlbDFAuBA_vS-W0PdhbqsuseWvezyeaXlldKSsoBW5TsSQkRBY6bQoXsjQCZ2MVBkf8WwdXu1ap9yWNpDxl-wsWuM41HNoqluj5BQ4BmLlVDSXkCa2DlbKZLckLeBSyy1ExgBPeKPtiOTPkaJiyo6DWytk8e42QEMF2_JY9-k6x6y2gfAA9qYK5FxYIXuxZi-sxJuzO-Plq90S8RBAeVzZHmBdigAaW2mhym7psDUhsH7IqZ5LEVGlri2VcnmMra1TT8uYCgMMDilc-P435piTCqmusnFD_rKVzKy2OeiPhubiVKRuwk9Yxe4uhTQAlTBGZI3cz79tqN-giWyB5nE6JwXmSLmkCWzvtz0iZa5Fcd0w0ieH0gq_gCas6HEPGW9Q_-Z-H26YOaG2Hk_ThhyncDCkz9lmKSU7EML1Nkyvh87LwiU-ytkjfXFuZMV9XloQdAwnzU0ielnrmOcuk8QBlTI5HaR2A6Qrc4iR2KYG_E8cEQkHo4THwxwTthyX4zCMrtacAq2x5AeoqFUqZkEYeu0Z-oQKbys4bVhd0QyuVC0fIVk=w765-h1019-no)

I also discovered this:
(https://lh3.googleusercontent.com/EU8Lj2DwjvQjWh7Os51TQftU1d20p4M2cNKdtOjZNkTZ6ilrY_18-ONCjGgVV7hQj7g6zpyn4fbQ6ELFnPZl1Y5nfHnlngIz-2mxrJ_6CQVnZ18Px1m2t6ITr8syK2K856iQawM-p3yGndMTKLQmsF3gHXOVUXWsP1A6wgY1ZUXcMXF8XfGK8Pr-wE9HoOel32OU-YovFGZ6hjjaebs4jYmHhryV-rhs7y9a6Bc0mc9VJMTJsDt5usVPp1tvACIW38zBNjkqwxEVPVyPJmrHq7oY9So6yKW-F0b4XuEi1qXtvt6FSz7WXaxIEiyKzouZuVchQ0H1G_JGMZjvUU32tadqLl6lGwe3i4IuyGLhjyiHQfyPCbhqDxLrt4IXMztjQWv_HcKO6cbCi4Yb3jJClX1Y4GVYPknn7aKrNPtDKvX8jYFY45qIgTGg4ATdtJvIwmqYDttNzgSOvuNGBbQzJeDMYdBx5od9pH3nhOtvStPoHg0nGgr1LJir-HGuRQopDrtdc2SHovuj6RciaHvYCL8cK7hxc-LVJXB78Ns3C8zym_Ol62NPzZdclOi2J0NHid0R13e0qSfMj4e9EiOft0fn_7YIJHk=w765-h1019-no)

This is the B168 bearing for 1" diameter shaft and 1.250" diameter bore which we initially ordered but found was wrong for the intermediate shaft to outer housing. it *was* correct in the parts catalog... The diagram just wasn't clear about which bearing was which.

ARP's:
(https://lh3.googleusercontent.com/VPXEPF4Lh3TU3IiTRFTjb70qgWIJ-qVmbSzgQzIsPzBebLWX3YLBlWabq7tIAEvZTKVXDmhYGFVxPz637RQuLJCWmffoFFsuY-MRTdnb31qHhhemakMcoqLCXeTFH2IvZBTAG0MazdJ3OhTASCtymnPB45TcVSNX8ar6m_dByx50xHrIkW_cpzkiqiA7cJr0aGANUXHtYMpkhasY4ANImzVa_jv7HJlzsmFDapi6LISFJ_JcBLNamuJeyq0riLLjkvflp9IcGyP-l7rbGJVwoiqn4Z7E4sPjfweJd7bLIMWv169kndyZ4Rm3xaRt49zoAbcyae95t5UdS8q4OXQEBXKShDryN9DabUjT0rtb1zoZh_HrqvX67wTnYgLkzWCB0aDHABn-_rQTpe7PeVGUf6ajkcNQKeRxQMzdR3KCKdInKsBVS00oaGlB2xJGGpIaB09M_ZLivd0qj9OZVJYcE7sXV05i_cgb_IXBNydKByIUJf6hdRFLzhEJpCKIP2QsAzBOVUNz9yXL2L-6HOHMDnIrhVN7M-0I3G8zHs9qdUiNPx7R2DC5QJ36PLYxvUbAEC0kKn5iZQSDO7nd__FWNvCs8KT8AmM=w765-h1019-no)

ARP's installed and pulled to 60 ftlbs:
(https://lh3.googleusercontent.com/roOwMvk34kJ_7Y1EYPkzwIDDj4phxHGSMPvWgQlAywHXjhr_VvPGZEWrAQ84lJTx7T2GWF2VYUDJ1L6f_Bpb_jAG7yz3heAYOSFfKr1pljeOHeE3Z73Wjym2BBZGq4tluwcJlDsabfKX7VYMa4lAM5bdqZp1Wte-ilcvbXv4dDGFn5UkLlRhkXlujxmmwPgtU1QjK10VeyWkussM8rEetw15faakcy5zZyTAsBjpb3kiOX9KVNxCRTfEyEkKUJxfilYnLBf6H1p9Y82Royc8S4hU5VH2kg__UzXa6oUuMly8nucN0TGnO5OcPwxRvl_gwLwnNlTfTjfNmcAiJZS8W8QY10McutxOgqX6LYrAWLI9fV7BIn-Zm4NyEy9c3ZdLGN04arfCm-ChWRMIF_s2FB5mKNMK7gLhUw7LqWvP22K7Zejr2u3jQq0ntbvm1Hv-sT_Kyoul90V53Q3zC-6Tkn-Dnkuk2AYQKxpp3nNL0hZCfJs5t3RwnAvB-5563jP_UCPQE9ittlDGiBNmIHkR0KGo5HAUZxIGF6OIexCfYgBYZGSvjHBooEGdrKO239PpX_dCoNTRHcXJZZCbbMXHwGLGjzb2zvo=w765-h1019-no)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on May 28, 2016, 01:24:18 PM
Of course I was an idiot and left the left output flange and the right bearing retainer at my house after I installed the speedy sleeve to the output flange and painted the bearing retainer.

This is the collection of hardware for the intermediate shaft and right output flange:

(https://lh3.googleusercontent.com/v9LADJIbCFbS4bIC_RoKkR2qlRqeah2YcNsT9i2sq_ss5d2H9uRkdUnRw6ysl7q-3iq4uMGeKWYeA2biG8ZYOxbMSMjYKD_bQdjwnIl6PzuQLGal6RuY_YA5rKOyRAESeqM7pkYCeQxlIwKo0fUZXHOHquo19j5uZzVTG49ufamH0GPjdACRThWHW-kFVEjrS3k4P79IDJfFRCxjfbUA4f3Yj6mmLqp-mNYFvYo13qR8Fso_Bz0N8LeaN5ODdC9kIVf7rQilupngN_WqvxbPU3axiOUbUyIjzuoMRYjWAWxVmpWkO_zfQ7xFNUdulp05wnfcceOOOQWsjtLzKNP_WFQ5kOPulXugnz2hTeAJ3K8bmaSIpA7O7rXvaUCgrSHJOl4oPJIdSN6seWYNrdE8r039jOpRKqijlByclxZ8GG0W2iZ_Nlm_jtG0mFoVspDRPO4KsQWgS3-owh68NKfHHaf8zoT9fiDfmeoDC8E7u0ddPZwC_e3vCDro-ULpZ9Q9DywtT1IBsVEiwHehll_G7FQlVQ_RxNNU0TQfZ_Iso3a280gLCXHNodpMVG5udfwoxheTADmbk4hqVq7tXqAe0exGIsUT5q4=w1359-h1019-no)

Here's the open IMS bearing bore viewed through the disconnect box:

(https://lh3.googleusercontent.com/xYHgO_2ofxAZLJ2tr7QLkm4BZg3EXANX8KkEmpU4tsnRElnqHS_-aBF1Baj67mEj_rL2OUN6Ehy2IE0J0qL7yAg-V5cc5Yduc4Byve_n5ZVS1zKrJVaSPLnRG9GyhjM9fuRp6c1YmCds6Ymi0Cqbm2ZQdPrhme-KBBH6N-tDFQngPoUYF9HpSJCDT5sG1FMy54ockZKzXDfq9L4iS1jkmJC7V10lkucNPyojz6pFXntIqDxfgFIlbEsP8cuHqH3KrpllfWY4PVAZDZeuHdSXzgpxgNJud3ciNgzu2_x9KXNf2KfDihrSMiyJAeHlKzofTps_0M9BtkfwitnEjhUrnpOV6cAnFzoawL1pQ_qyzmwanZO2EUvab65VsUBQvmlBvkgLrGYYUadPyAj4aw94vFLfIyr_A7W1d2R3_nrxUxj2vpxWSZZZOe-76lYQFEgydcUc81BdYaM0pssVvRdQHT_bUBk2SGyMiwd52QHKWsYVXQCdl0D-HzuWhJCZNT8uPs61BQN6KWFjceCTLP6kG5Lza_gBgXGgdPkP0dwQg7D-9nsKP9lli0m2JZ7UWXSpxu9KqjyyQM4rmtNbzdwVhAlilhn-M90=w765-h1019-no)

Bearing installed:

(https://lh3.googleusercontent.com/FdLyL_rnpmD5jc7SPKMQhSFWQR_iO1k8JJq-N0xCO7Qy5-5tSOeeUxwTJ1jAG72OevCLjB80pMir9zDMJNVMCWPSs3maD3qOzcl7mDV_bQt0KgzzLRDlkRl09MSQd00UioxVxwSVpJe792hvwfG15vu90LrGCviLGQ8L16CoZzvJKuDaqpINaByqB5B8QlgbF45YR1-tV2CbHkyxm2DTbiJH31HXSpODjAGrUG6YZGcDdYefNQr1Z3V-tLEoZ-R9oJq-MlOUDy_yEtsuJtEx2KmDU_Diw3FUPz8Mqstxnovj5z2Lq86hgaZdbHJooJnKV5-Ilhn0WZgJr7MvJgt73Z1Zcd-fpYHO_1oXIXvaCHVtij6oBbakxaKplZqN6veo3u9IFi_FWZKK4ELkxESrajv4V3JPpP1E4TEUqapvshB4eWU5gd0iVeZRY7ZXrG5g0b-D20_Yo44jT77AaSj8vGFJuphCVKwY5Qz3Q6SnRlpxwrgWS3PqSZ01dD9y-Ie3u19SE5EY4qp3URmnBjVbp8RXFABSnU7xFrRDzuVF2eVcclOMB0XqpOm-CK-2CfPEp-dmwr1-c_t9CvRLbW6ecP8as3pvKQw=w765-h1019-no)

Shaft, with its internal bearing, and shift collar installed:

(https://lh3.googleusercontent.com/65ll3WDtA1bcZ4TeXUClEdi8NmsXLe-jjoq7JnPLrAgZC_YnTHLVHiHzPaeq2IKXPjAH8RIUPySytFjhn2VyefTWwO7INNR6gx-90EjPJj21SJ9v-AAZXcBy0D0dZ9v5PX7y7UxHFY_pt43asMWTweJgKVXZnGGi_aOKBBoEdSe2xisd0ZUx9OqiFWlvt2RgHP-zCUOp1Wbi-2n4QySpuVuZ1BCh22zzlZHF-zaXIs7K6nzT6eYBUDG2vwt2IH7RtJ_bvaFoABVO6ozSC-jNvF2KCIVZk4ftHjhfy8MHHMNbUIHHh5shIocyrhRlYsZBIasfVTGJoj-I4CNgSAU5RAl9S6o4eeppBlTHNvYtPvwSSfPCcAjP0fSdY8SKI9QhPSCSNCu1Rg1M8mx6KL0haJutUJHEy4lCXP0l_mQqE4Kmer3zU3aEcCggf6ZdgqCS_MVqVaHmE_f_nfTvSymiSuxyXcf3S9-iRdVILhyoIiZnKK9MkSEPCNiPTsTO1uFF4h0uWtuZBSqrZUXOhsTDeMIbD-XsfJOl3E3gVYLQRhEQIZ0-2X3-fYage-lJoVfpt-6617Dl4Hs7tu3-a4PXJBfuP2ZgM5Q=w765-h1019-no)

The collar has to slide in through the disco box opening, then the shaft drops down through it. It's awkward, but that's the way they did it.

Now I'm looking for the C-clips... however, they're not typical C-clips. They're more like super heavy duty E-clips... IIRC, they were somewhat spring loaded, which is what kept them in place. I was able to remove them without removing the diff cross-pin, so they weren't what is typically thought of as C-clips.

The C-clip part number is 813 0763, but googling that just turns up my own topic!
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on May 28, 2016, 06:55:05 PM
I found a bunch of places with kits that show the :water reservoir: part, but no one lists it separately. I got a hold of 4wd.com and the guy knew the part, but also knew they didn't sell it separately.

http://www.shopjeepparts.com/ring-pinion-reverse-rotation-ratio-dana-disconnect-p-6190.html?osCsid=o9k2019mm989h13ep8n0r1dbf2
http://www.shopjeepparts.com/rebuild-bearings-seal-shims-hardware-dana-with-disconnect-p-6178.html
http://www.4wd.com/Jeep-Drivetrain-Jeep-Axles-Differentials/Dana-30-Carrier-Shim-Kit.aspx?t_c=12&t_s=514&t_pt=7257&t_pn=CRO83500191
http://www.4wd.com/Jeep-Drivetrain-Jeep-Axles-Differentials/Dana-30-Differential-Shim-Kit.aspx?t_c=12&t_s=514&t_pt=9181&t_pn=OAI16512.05
http://www.4wd.com/Jeep-Drivetrain-Jeep-Axles-Differentials/Dana-30-Differential-Gear-Set.aspx?t_c=12&t_s=514&t_pt=7961&t_pn=OAI16507.03

Apparently enough people break the disco cover that it's readily available by itself, and the price isn't bad:
http://www.4wheelparts.com/Drivetrain-Differential/Dana-Spicer-Axle-Disconnect-Actuator-Cover.aspx?t_c=12&t_s=237&t_pt=101224&t_pn=D%2fS42208

I can just buy that and the appropriate ancillary parts and set up the indicator switch right away.

And a cast iron disco shift fork:
http://www.4wheelparts.com/Drivetrain-Differential/Dana-30-44-Cast-Iron-Shift-Fork.aspx?t_c=12&t_s=237&t_pt=101224&t_pn=ALY450100
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on June 01, 2016, 08:05:49 PM
CarQuest couldn't cross the AMC part number and didn't have a listing for the snap ring.
I swung by a dealer tonight and got the succession of PN's this part has had: AMC 8130763 became Chryco J8130763 which became 4137739 which became 5252775. Of course they don't have any. The counter man was able to give me contact info for a couple different dealerships within a few hundred miles which showed 1 or two in inventory. Before I do that, I tap the endless knowledge of the internet.

Googling these numbers turns up this page:

http://www.moparpartsgiant.com/parts-list/1997-jeep-wrangler/front-suspension-drive-differential-front-axle.html

Where the clip appears to be callout #17

(http://www.moparpartsgiant.com/diagrams/large/7/9/00i57197.png)


While this site doesn't have a photo of the specific part, the combo of the callout in the exploded diagram and the two part numbers the dealership gave me being listed makes me confident enough to put the $5 at risk and order a couple.

A good many of the search results also mention '98 Dodge Dakotas and similar. This appears to be a commonly used, but not commonly replaced, part.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on June 11, 2016, 02:59:54 PM
The clips arrived:

(https://lh3.googleusercontent.com/gDpeJ8Oa1NHtg3W-OhgbjJhmmQc0PFN4KJ4bZBt3enHB08mcRDT6aecBQ5ki1nJqVmtE2aoU5aKFb22IzcIpxOYLnBlbYzpc4ylU8bYQlW_vy07AvfkJMCyEGgFBbZJYqYGPHi8jjV_UqqxnT_TperSihtHyJ2Ub_SKHwkXXMVF1By6gFL0VyAYaz2edXIdSDbV1PZHRacMtflHWiCsjVmMiG_iFAo2qvumw-hGEytjjoLiwgD7xIxVOv7C6gnmCv0YNM2wdkYdY-El7UaPaFOTwh_xIckzk5Fc7VTq6O_ie_KEXOnYx8IqHpmkTGpGFfcp60sWwFJ7u01aETqrVewODtKFvafw-tJfsS3pQ68-w9pARyd9k85ILvrvJJAYN5j-Fs14U5rcKeGrRnIlVGs7NCODckigyujq-AWj_xQ_BrOfu5lBpVHhE4YgPO7-IxMpWhucJuOraRZoibKtAS6EEv1y1YIPNdu7cMDR8Gyo1PPJuuVmix_zr4BVG0fdDY8amgJoflsZ7j2ioTCrlxvy9DP_SBhwutQIB6wAUSabEncCuMIYk7qM-wyZe3r30763MEXlr504gaf4a7c6z0nh_l9HdVuw=w246-h328-no)

The minor diameter of the groove is 0.868, probably a nominal 0.875 and its width is 0.086. The clips are 0.077 thick.
McMaster PN 98420A157 appears to be *EXACTLY* the part that Dana/Spicer used. They even give the nomenclature for that style of E-ring as "poodle rings". McMaster sells a 10 pack for $8.10, which sure is better pricing than the Jeep aftermarket has.
McMaster link: http://www.mcmaster.com/#98420a157/=12t68c9

(https://www.mcmaster.com/mva/library/20170501/98420a157_heavy%20duty%20side-mount%20external%20retaining%20ringl.gif)




This is the LEFT output flange bearing.
(https://lh3.googleusercontent.com/-ukY3Xmu2ZDXWCqhtq4ZNoVOXG3u4_IKk8X3aUgrE4TMCGMy1wW3JOcjA0UN6f1ng6XQTDbLyVddTVWEBE5N_nodkwHqV2JXogcvxXTPa-ajW51aB0SieDRf_eUehkJvhu3pDuHPYosRnDdjDyNDsmKEB7cxoNTUxDEDUeQ23WZUm1Pq3wjfd9RDV3OfvuN7vhGZchoYuRTE_cd3SROtpP_DJQJZPkoXrs34kbZW68IKHmjxJDZxpcauaIU3nTyGsEj9T6gvyC7iCeymEYW5wrh_zYzfT_8u856pW5AzMa3ZaF1vHnoeFun0qK7Mh3BaBLcuiH4-kEfTp51jc2b8gd3EP2stHopZg0bGGg-KpPj50jBsp4sStUhSWZwn7EQ7jZ8VEKiAEek3Rvmd2MH1JcU2Srj4ihe9h5Jxj5lgYRe79H3nAC9cAH_5ZCLBqJ2dGM8DSZsT5YmV5naKfhxXxObG9kAkkKvRTY3OPCq2SGBBK8y-NsW5LUN9-h69La2Bnlo-JgT44UlXk_coCpQmn7hLNvLdIEU-4d5JHcaxnelOMkJefCgDk5mFH1LfkDx6n19E9St-dlDmQQOjuJnoD7ZmUsKPNdU=w765-h1019-no)

This is the right output flange installed:
(https://lh3.googleusercontent.com/GrRoE_6bD3swdcwOzDF3EwrUIL0Rq8GQW6ZmCtKNtHQ9Zwz1odZhIzU1zKnIARdUJTHzqRHY9q9EXOn5q6nwXa0JchN2g3DF6oI0nYu-HOOcCm5MrBCyTLk1CkVqumaaekBgeTFdMUX1rFC_1jvQPZuIJ_O0WfwOrYnBFZkDOkPpj4FDdsN4_PBFGHqhWJYPCt5DPvEtpB0p-h0rXIepNzhfFPsAlyUn7fOeywMkLHxnWB7QBOaSXy3RA_pyIoGPuGN-IwVriafC-JPD1IkH90Upqd5JgfirD1GYGrzm8MRG_K1oOPy4asmo15tO-ipLuBKx9zc2iXNqDaryFpGMCc-nPaMW_r8FtH5QDcmodVvRXm9vhRSg2uFJNb1W0hawnZRKaxAFA5TsLGTlSVi3BaPMa1uqDauBPlzyGQPWOTS11nQGUnlcOBTJKn2vFFi0QGvLslosnzjgfPCvRNtMAFF7wD741l4K85nFHqCAiFtnp2Fq5pGPM6iEawhUlV7AoC68dD1oqY9SEnJrO1Soi14bi2yUu68XpDzvPWa9WOcTsxXgcjyaOYdqlZp-VAWM6AyMhSN_y3fLhHJQGNK866fHYAEK3rg=w765-h1019-no)
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on July 01, 2016, 05:31:04 PM
LOL at my luck. This thing just keeps fighting me.

First, with the speedy sleeve the left output flange wouldn't go in all the way, or at least not far enough to install the clip. Originally it went in far enough to contact the cross-pin. I put some feeler gauges in between and came up with 0.054. A machinist my dad knows (a different one this time) *carefully* cut the end of the speedy sleeve back by 0.060". The sleeve is only 0.010" thick, so trying to cut it might have just spun the sleeve on the flange, which would be a bad day and a ruined $27 sleeve.

Here's the result. I'm surprised that the extent of the sleeve is visible:

(https://lh3.googleusercontent.com/7NZQJiFcA68yXZsIv0wIXIQM8xq9XZSoKC6I4p8cfFSxvGCsJ15gj6RxUPdXrt7ZQa5BtokxLuOIG3aWAdzeo8Mpr73B4PqvQt3RGJhsLktKhd10Rzrd3csHa2ypyWoW39lRbOeVDyaEgYyyTHNO0Cc__BWpIzlN1dDz2BZAw1-oYaOQgX8AySNagmsuSSDCcuEn2-rS4s8s2B3MWO6mQayp1Tn0APqaMBYiyIzGwO5tOo-0yTxGs_-d9uMkDzbVon_MA3h0yfJJK2dcVwwW4r08VDm5Qv7tHuo0KUsK4jlCLAuXtWQvvbNcOI_gbsmxIjf0UTXFtRxcTeX0hXk2yN4RASiXHOa1NDc1ZcGt8hmslV5K29kz2LsDs0AsS2vCyYRip0HuA6-nOCZ9eKlZx2_IcYEE7CyofRJlttvTnHHkgVC8aFjSm2AXDFacd1L86R2A8UpVPC3Bt2MZOIG0RCqvn_XWq93eeZXJQHrzRVSJj9Nsy55lmBjmTO_DppxV5nZvqtIhxfbi7nxDaWI-tANZFfdxvhlC3oC-raoPQaHjbYnablaf5XCheq04JhUeEons3U9pABO4zg13TlwsXnn6mTqgMjc=w765-h1019-no)

I tried to install the seal and then drop the flange in, pop in the clip and be done except for the covers, but that was not to be.
The seal I have is the wrong one. After talking with the CarQuest proprietor, we figured out all the right part numbers (AMC & Timken) per the parts diagram and the orignal part mark, but she couldn't get either of them. Besides, none of the dimensions for those parts were right. The seal required is for a 1.375" shaft and 2.440 bore. Neither of the AMC part numbers crossed to a seal with those specs.

I found the Timken seal catalog here: http://www.timken.com/en-us/products/documents/seal-specification-guide.pdf
And was able to look up the diametral specs and find Timken PN 470950, which is the same style #407 as the other two, but made for the right dimensions. One of those will be in tomorrow. I have no idea why the AMC PN's and the original part mark didn't cross to something I can use.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on July 03, 2016, 09:13:55 AM
Correct PN 470950 seal installed:

(https://lh3.googleusercontent.com/2JgSEtPMVbKtgPUFxzD1yNy8g2LWNyusN1NpjmbNLKpxwg9hg1PRWXvi0UIfz4CZEWa7W0MvYOp-OkdfUyTC56T-Umsn_zZeRemwzEQ4Wd7HEI-oAuQ_cQH2KRrL0g4K2xTwl-7JAv0tAjf5_rf0hbnoBhJtbSpo0kIoiVk9t_OTcxc3YQr3i60n6NN9xw33d-jhyoy3L03Cc-R-TrGOUIoWp_8--G2jUAGMGfEntcApP3bdEDaHguf_KGnEuSMhPPYsk_6sTi_DqYvivMTHQb3J_G58zvIGNmpYqNPzdd2S1mHLpe-RHGWGK18UzUu0z45YY35YQDEEJ2h9XglIhIvf72OIHEn8NiWjd40R0ZYCZvLK59GHKWCLCMNQFBsySA7BI3PPC_VxcfAEbhLm-u0luJcR9pKKYWYU8iuL_q8Osw-WN1s0PKjBEU46hATg9_2yYRfCaRNw42uJEu_IayhNGwxAZCHPs4DIL13nT5zb3s9anz0s_Dqa7LpTkjrdXwEeEB8Sh39UkdOr0cyQpwo5DSubJvcAcfigbGWTZv7OajdH1UZ4Iv87WkV8sSsFpoaYsG2aGi2Qph_89_15tQrshUellqA=w765-h1019-no)

Left output flange installed:
(https://lh3.googleusercontent.com/2KpO_KU4uNYFp8-dklzAIcsSDLxQFmwrlZfEYEkwnTeGf-5PWzoK-XbTzoPdJBrFNp-ylCalzRkj5PtUayAvdH1H4xmk2dfEtNhwOA8Ul1mNYO_a0sggl5pG6Utvb1TyvbeoT0rm-CZUK6ulm_n6kAl35OeHJ6xl4Uj34i93ndWKg-G4Tsx1pD5KhTfkWEqJHJgMoL-hkQ58EFwUa8N00SH2KKQF9svsCa2pPsh33lBsayrJ3hTNaPrjrPvyJwlVyT3kMlVhBrtI56SKQdcYtu2OpwmrE9oETmqi4LICMG3TOHDG9E5JTaotsP0_FttYQHK7OeNGL5qw3sdRh8aplAdX0gnlHz7buazIsLIqT9RtfqhgJcJw8MpWdw7EqsoiTdPN6Kq1NNBbtkv8vSWYmeKZltTHeAiI8z9-K1BAzcD_dCYMCAsZ9FrxkNFnsONh79B5RCkiZ5RCKt40WCvZpZnYzda7HXzmKTtNa6J8-dEn4U3u77kJyJMcxgY_JyOmeuJO64HQJzTWBgErWhM8GPZpxXSJP8iqv51cT6vER186LhByR4-vbtYFL84SMmNtObsqN6-LFOLSLWAMKbh8b7Dc2EXXj84=w765-h1019-no)

Clips installed:
(https://lh3.googleusercontent.com/l4n3svpaiDV-LXJKDJLI2s8sVzhXx0FyYb2-Bx5LEeVJEJFX_ZUkk9JSysQBpEFDkEfBBWq-sAtdcdNfNTlZ83xRpEl04GBTekR8ofumWizWF6xoQzmQafPYCjuFLD1Do4c2fPUqbtYc8A-T5ctjtO8C7lkm8ac9WY5o6T0ePAklFhE06GZC_Vd-ap4Z2qL_m8HRNJLmrXAkdouMjZOH2HPliYf6vrRrS89aqdeIuMD0FeeLxT7vGzj0A7u8wjU-pKvvocG-Bb7ZNGMKUz6a0uoEtA3N9rt-FfZPovHwmmuQ44FIn1N_EehTSygWtkmRGou-VJOzwuNWYdOfHjKF0CbJXGFe7akLFwmR-3zoOmr1DRj2sPSfGQas5nddFcKX_0PaRfK3L2a2ydgndCHd_XjfbUiSu99tEkwgOTSAtINjxfybRFv73JzzBmM3VRdb7TIl0SNwTuyUkA4-NgLMUi07s4xzgDC-INnyGpAOJGQ6-umR8nzTP5fSRb18Mejl-ICHCqKbymGfZi4LyjSNNkBmnx1DFiJQpbnsclnzEQOU6YEAIVi5ysQXb0rZcAbMP-Fc2ZpTX9ZHvzhHZvQbCc6i2wQoCpw=w765-h1019-no)

This is how the right output flange bearing retainer bolts need to be torqued (144 inlbs on a 1/4" socket cap!):

(https://lh3.googleusercontent.com/WyUpLhoFNAh2_Jf1C5RQufe-zCuKrb5VwcrRd4JyIaYpVue6HQMGIYRnYyROPmF3LQ0xfcsoo-PsA_8lRacanu2Lv3V4PtMbOftRx0d5U-zj1nxL1Hqg9zbYK35jnvklleS2-e_Fr0hJwOkVXPrfqhpgGPgTZw8kFRaRMLTGExxObaEGiy4c9ViOWK_5x-Wi5Z-WmDF7dl12MO6O2qhhzJSUODJlFhpdyql9fMPS1Z-XnPCm1W6MasD8IGTmwUej_uFsBSHiQGqmBY8EfM6nH0q64pO4bpQh-yVATWWBqU1OZ19e-RERGcpIqm4gcIeAPnXFe3C7pj-VnDYoI4W5BkH1dpn3falpfFQXEKA5_IRHjZxOQcxSHEwPJDEPl_IkPcrShos6QwfQ2pG8etxIvPYSlLb6trE46ZlGCN0UUSM5VBnxOv-gF0hmmjEFbOcn_ICL7SLnoVEFTQHM2aHW3eP97t9Vl4ThAgbZiF7yc4IjiFZKCY5Uja7Uq-qHQNiJB4WMP1T0_bEzmfNLikk7INo4C07vnH4D5pirAheZXL82Kza5Bi25gu391VhhF-ck8AmAUDfCEjxR_dNsHoUXYcKTKV0fHeA=w765-h1019-no)

And I disassembled and cleaned the disco housing cover and servo. The servo diaphragm shell is bent and the shaft shaft scrapes like it has a bunch of rust and trash in it. It held vacuum when we started playing with it, but now doesn't, so now I'm in the hunt for a new actuator.
I haven't done a lot of research yet, but I don't know if the AMC Eagle actuator is the same as the one used on Jeeps. It wasn't much longer after Chrysler bought AMC that Jeeps with disconnects started using an electric switch to verify the position of the disconnect. The AMC system is entirely vacuum operated. The 2WD/AWD switch inside the vehicle is simply a valve that applies vacuum to the axle disconnect actuator. The stem of that actuator includes a valve that opens when the actuator reaches its end position. That second valve applies vacuum to the transfer case 2WD/AWD selector servo, so the axle engages before the T-case does. In the Jeeps, the vacuum servo operates (I *@$$ume* via a solenoid valve) and the position switch indicates when the servo has done its job, presumably enabling another solenoid to operate the T-case servo. I don't *think* Jeeps had axle disconnects before Chrysler took over, so I'm not expecting to find Jeep parts to replace the AMC part. I may need to convert to the later Jeep electro-vacuum system due to parts availability.

(https://lh3.googleusercontent.com/3yd5grFSYiI1nKPGuZ0c9j6cClo-yxKkNYCVmmtjKuPlmniPPN1oz_Ys5_3TouWhGNgjLskCGNmby56I6nu_WqPelMkAl1gfMwgxSgYOldGr349nvisBxC20gIWffzBgwqIHayx_mAGS0mdK7WQVVX1gF_PRRrjye4P71yvBwLeXyNnhHHotXubfzkIvYlAcsXzXNaGa_WqVVnEhO7OPOMoRpG1x62ziMh6i4vcjKSwDx9gTXL43Hepm4AB68nsJJUSJNxLGPuqGFUg8-C592foSy33fzAJ6GI7kOLFXemYk6pcxspvMD9Z_xme2taGWuZF56ewtIS9baNTpm-y3m-Y41oT1-33mckux1DoIqIfUYqQWB79uHvEYWyMT_mYVvJwG102T5c8OmBhBmC0GE9uwTigytW98eU6dxdKJM6q8X5O-HP0a1_-NyXJcnmq7-oEO0xJRbWuIyQyE-Olivv-5kCClIrdSiy2mSzuKvxQzzaoEC4TkZ-CAEsssiJ78iwWuDs62McF68zhCvNFax308gMM5aTiBM6admbOLUf9_ZuTfz4rKrQISmNYop0b5Q5oChMEBPAy6U0ydGLvjYwziNeLnOKM=w765-h1019-no)


Eagle's Den forum topics on the actuator:
http://forums.amceaglesden.com/index.php?topic=39361.0
http://forums.amceaglesden.com/index.php?topic=37665.0
http://forums.amceaglesden.com/index.php?topic=40936.0 (I replied in 2013?)

The Dorman 600-200 actuator is for Cherokees and such, but Dorman may have a replacement Eagle actuator for me to find: http://www.dormanproducts.com/itemdetail.aspx?ProductID=28487&SEName=600-200

A thread showing bits of another 4.0 swap: http://theamcforum.com/forum/amc-eagle-front-axle-diff-cover-removal_topic42455.html

Comparison between Jeep and Eagle disco covers: http://wiki.amcevolution.com/index.php/Front_Axle_Lock
If the covers aren't the same depth, then I may not be able to swap the Jeep parts right on like I was hoping... Do I want to extend the shift fork if the Jeep cover is deeper than the Eagle cover?

Reasonably cool video of an Eagle SX/4 in action. He still has the independent front suspension for the first half of the video.
https://www.youtube.com/watch?v=EcXC5IUOdFk
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on August 27, 2016, 10:34:07 PM
Here's the later model Jeep axle disconnect actuator next to the Eagle actuator. The 4 port Eagle actuator includes a secondary valve which connects the two ports on the shank once the actuator hits the end of its travel and the axle is connected.
The Jeep actuator connects the port on the shank to the vacuum applied to the gold side of the diaphragm when connecting the axle... so it does exactly the same thing as the Eagle actuator, except with one fewer hose.
Both actuators break the connection to the "output" port on the shank when the actuator retracts to disconnect the axle, by putting vacuum to the plastic end cap over the diaphragm.

(https://lh3.googleusercontent.com/yA0q42uRvbotsG4iVYj1NbOz7kop6HeTke9Ik8x5WqpccQ_LpMtQmweU_W1gZTF7gBHpzGUzgv4JpDUF3dw6JevqTFhFhL4u1LamN5KSUF8fWGLc1HKXv_-qFsafLp1-ov906w_0Jp2jADGX7yvvMQo-of3FQrSCzGDYRpdI8ao9MP9S5DOyDdnAZKs_QpnHheHk1H3ww-B937w2xxBtpIG3rj5HxITIba0UmJ2E1G3BezVaMO5HRrQSgnrWfAyz0-lBGAAyL2Yf1PSE8vsBDNWGQ5wD8rsJYeXL0JJ7RQ4SsTXy60gMhHBs3od-IQgsXZqU0luPKVvncAID2BH8IJHeo-Y4T6KO6fPLp-4c4O3QH3W0q5DKO2KqLWrqkYrk0zNLQUdfYk_3q6QrjiRVYTI1iMRDnXrJR_gfutHKMJAHbeWlrPhwnsFlwuBfTbqTk57YYQUHfnaeGpOy5_h2eSyb2DDW1KKv-U8p9TU5-c6ubJMWgOO_i1glZxiv-z2OTFaOXrVycwmEm2KIdli9XXLFlyfvfU8yPP-6kEa9-iRcAP6xXpPIC8hl5nQtKLSE5IFnfplyAuiaOQUEw7o_eNhdz9dvd-5yLnbvJTxFicu9E5AL=w1359-h1019-no)

And the Jeep actuator went together with the Eagle disco housing cover and shift fork just as well as stock.

(https://lh3.googleusercontent.com/EgrYlRVpUT18778_AARn3RMBO8G6HYlaYkkokPygW9hvyk-Fd-qR-dY1ajQh8uHOiIJg7KWBdUs8OO76kK-lue4w3JEbnsDTq4KbCIJ_586KXkoC2CbDgTSnHTCovQ0NgCWq13HNPuq_bDNSv8sWTCKhnS62LyWQtrgTRTj0ykCBecaKtOM6WcVTUsS3ic0o-aEhtBiq1KgCjxQsMYKtlx01aX3Cu0KfP8ryfHa_PTpeHK_Km5YrJy5YCqrUmLzLnBNoDR2RGxDN3KBnq_lTLHw27BB7RksMuvK-k_yVR7jQ5jggB5KeZJz6_yHYeT8XM-GhrRtFRftZ0bDySdDEmJre2C3RV_8DaKxk9UM-JU2aqKqCxWDgxv7aFXnO7MExxAwrrQh_wUVMucSAE5FVvuztduGTQ0672OYvk894n2MXCQPQ0vXe5ihALseD5KONzHNuOxn3CjTqvkH1UtHO5_n682RV6Awtso-htwFpVA9jBEwPPIVdLmSK8Azlt_iu8s-2QY3kfS3wFxRUt1y7P3-Hc8-pWoWeCXhl9SBXs07tBzl6FjztzHKTceWIjUCQ8hljv-LIjAXkdejHs-ca-OWbT6erBjtTled_PmybDDaXcRHr=w765-h1019-no)

Here's the dern thing installed while I fill the pumpkin with 3 pints of 80W90 Amsoil synthetic gear oil

(https://lh3.googleusercontent.com/xZJ5LoDtF4XKq578PqPHYigh4V26PjWhNgqVuQx-MxIDG52cJAjDolY056EuWEdEc_gQhJ1OARNEnA6dyXjWhcW5fo0MUcysBZZG6DLpJb3whlK1XJpCUrmNb2bH1iPcV91UeCNnIze197uKLel_ZZkTA0dovDOCOTjK08H73E0UYt-nqj5_hbZcQNnlymtbfhbPhoSQ7UaF9VMH04jA61n0ORJEln7iYSuojnbEkPPz2p_96n8d9eaUU5ALfpVtyIRIlRCM58RMeDHz9Pm0Mg8DzEaNqDf4tDCHmCClczXCy-M_7qd8NSSDwO398myFkZ7YrpXbEVnPSkvrQ3bj7hrUQJiGh3nLrNeJ7qmtQLOi7Yxolqz21XRYYEMg8zCPX2tDo5nsunuB9OMj7sE-OjtKFNS4NezuK7mNJ0vKS4czWctc9pfuk4P2latKOzrAzhgffWqfPeRWC37oOz_v9gW0jmHuLrT7f7Hjl6KcfgFAx_ppl2Ep4facEx9emESP3dCdB9Z4Rikrq2O1h4IGUxrGE2PimHsZmR2f2PkEGjMltfIzWueavizXkuL_X9cM747vrrbtwqQWvdrGfbtS_81wjUBdlndHYg5JmK6Rt4JId7Mh=w1359-h1019-no)

Gear oil:

(https://lh3.googleusercontent.com/3IBtjoYgG1sPCfLI2A2vxxJwCcU4I87Tn95FEs6ezh39Ge8ovh-6uMu1rycYZvVxA6-TQK0XxGApEeyPBs6BMZk7xyY24D-VJ6gXrs7d_oEzMlL17NDGI8Gz8TNzB7qd6ZkA16KqvAUMUsktK0-3SI2Xi_Unfi5kxibNvxWvBo5vZcrzYM98KRtN7bwvk0Shm_7zEF0oF52QdbLtJLc5dqO3xv-pnOdjLe6rVS_5W_fxHCJzh5L7_fRmLXf0NQhi6T4HISHgzj8jlDM78AkRsPY5SU8hXOaistv-njWWBjd4jDrKWqaW84HYRCKd53dkpK-HAw58pGcDdGCWa-BK8a0uYDRJOFNon6_7XBfxayBzpoCW-k955JXtjkWHDudQe3cTXkSknuwWBwjnh2EDaA1QWAZMQLLEu70FFO1xB-Gg2nlwHHhy2KHS1QXfK-41sdULj3qPeFZLwfkMhj4o-sRjacpfjTmlv6m_gV2hajScRPQcARfXfjrH6b8wp3Evfhn7Lm7D-k9oRh71GbenoQqBSGi_j5I4p1kYWuBct0ylICPPWOvErDJ0w-8-54FSLvLd4YGYQu0gB5VYrVtCSOPfWE0Zszl65lYwelPn6zJk-hR_=w1359-h1019-no)

WTF? The ratio tag doesn't fit anymore:

(https://lh3.googleusercontent.com/TSRL-nevjuuOek4MNQ-b75-YAzHuXqYTDfTP1CxtCMeXkkAHJ4xanT_czTV7s1iuWQJpoUc1JD2sTNzUjBsteR9kDLioeCg2GllDER5hCT0ezsftCP3Kl45YgK1TSn0euqoSUV4NoyXGDuR414VW-3fZM_x6rjKE8ukPyDtdSdt92gmiPKo9gN8aVkyTUf0zcU-ZH9MgxPuKVm1b-Co_PzH88j0Dd3QgVYmBnUWM7xVdYEjqARQzTAphMQ1_SNvEUO_SonqCuIvl4pFETvszAps4xuYdmpYVhVqIhHq9I7UsBlG1FXCBowfwYRBAzjPTtsafghgoywwY3SiQeT5fyBvoRt-nx8rHxENxFHRWbD7-HizU4u7TBVkQ4BDezz9asQH4rX74VdGXwoVN2pkFsYdAs_WobQTY0IyKZ3DKlgWzgmtvIpugznD53rplRKbZ-6sa9DhhzDgsTAInV4NhNVNN5lgkbgKaZoxul1a8twgRRzypc-7dqWOrFKetuxibX-RaYGG5-VgkOmTz44ryb_Qmrxh-7Kbnbi_O-ktcEeD_G0MoEdw_AJfYqAuRhaotQEDdPOwer-R_i6WXIKKKoxeHMl9mblaunMmXlUA0099jLIrH=w1359-h1019-no)

I didn't grab a pic of it tonight, but the diff is all buttoned back up and hanging off the side of the engine like it should. I'm stoked that's finally in place.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: amcfool1 on August 27, 2016, 11:06:08 PM
hi, good work! Let us know how the Jeep vac disconnect actually works. You may have found a solution to a longstanding Eagle problem. When I repaired my first Eagle, waaaay back in the mid 90s. The vac disconnect motors were still available, so I bought one of each, and even then, they were not cheap, about $125./each. good luck, gz
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on June 02, 2018, 06:53:07 PM
Do Eagle Dana 30's have 27 spline side gears?

I'm about to order an Eaton E-Locker and want to make sure I have the right part.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: djm3452004 on May 08, 2019, 02:08:04 PM
Hi All --

After reading this thread and several Jeep Dana 30 pinion seal replacement articles online, I had a question regarding changing the front pinion seal on our Dana 30 IFS axles.
 
For my situation, I have no reason to remove the diff. case or pinion as the bearings are fine, just want to replace the pinion seal.
 
If there is no crush sleeve or spacers to worry about as this thread mentioned (12/25/2015), do I count the unused threads on the pinion and mark the nut, pinion and yoke during disassembly, then ensure that these marks line up again when retorqueing the nut back down to spec. after the pinion seal is replaced?

I would have loved to have started this as a new topic but the CleanTalk filter seemed to have a problem with something I’d typed above and wouldn’t let me post.

Thanks in advance for any thoughts --
David
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: Taylor on May 08, 2019, 09:08:05 PM
Great and informative thread.
As for the clean talk spam filter. I will start a separate thread specifically for that issue.
But for now I do think helps more than hurts.
Taylor
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: derf on May 09, 2019, 05:50:19 PM
Hi All --

After reading this thread and several Jeep Dana 30 pinion seal replacement articles online, I had a question regarding changing the front pinion seal on our Dana 30 IFS axles.
 
For my situation, I have no reason to remove the diff. case or pinion as the bearings are fine, just want to replace the pinion seal.
 
If there is no crush sleeve or spacers to worry about as this thread mentioned (12/25/2015), do I count the unused threads on the pinion and mark the nut, pinion and yoke during disassembly, then ensure that these marks line up again when retorqueing the nut back down to spec. after the pinion seal is replaced?

I would have loved to have started this as a new topic but the CleanTalk filter seemed to have a problem with something I’d typed above and wouldn’t let me post.

Thanks in advance for any thoughts --
David

Every time I replace a pinion seal, I break out the torque wrench and torque the nut back to spec.  That's the single best way to be sure you get the right preload on the bearings.  Doing it any other way has the potential to be way off.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: djm3452004 on May 10, 2019, 09:25:52 AM

"Every time I replace a pinion seal, I break out the torque wrench and torque the nut back to spec.  That's the single best way to be sure you get the right preload on the bearings.  Doing it any other way has the potential to be way off. -- derf"



Thanks for your reply!  :)

So there are no crush sleeves or spacers to worry about replacing to set the preload since I'm not removing the pinion/diff. case, correct? 

I was under the impression from looking around online that some Dana 30s did have the crush sleeves that *could* require replacement, but it doesn't seem to be the case for our Eagle differentials...

Thank you!

David


Title: Re: Overhauling Disco front diff: Parts list or references
Post by: derf on May 10, 2019, 10:02:13 AM

"Every time I replace a pinion seal, I break out the torque wrench and torque the nut back to spec.  That's the single best way to be sure you get the right preload on the bearings.  Doing it any other way has the potential to be way off. -- derf"



Thanks for your reply!  :)

So there are no crush sleeves or spacers to worry about replacing to set the preload since I'm not removing the pinion/diff. case, correct? 

I was under the impression from looking around online that some Dana 30s did have the crush sleeves that *could* require replacement, but it doesn't seem to be the case for our Eagle differentials...

Thank you!

David

I don't believe they switched to a crush sleeve until well after the Eagle was discontinued.  I did have one on my 2012 Wrangler but that's a completely redesigned differential.

However, even if it does have a crush sleeve, the torque spec isn't enough to crush it any more than it's already been crushed.  You have to put a good 250-300 ft-lbs or more to get the sleeve to crush.  The torque spec for the pinion nut comes in well below that for the pinion nut once you have the preload dialed in.

In fact, when I did the gear swap on the Wrangler, we disassembled and reassembled it to finish it up after crushing the sleeve.  We used the old pinion nut from the other gear set to crush the sleeve.  Took that off, put the pinion seal in and used the new pinion nut to finish it.  Torqued it to spec and the preload was just about exactly the same.

Get a good torque wrench, torque it to spec.

It helps to have a big pipe wrench on the pinion yoke to hold it in place while you're torquing the nut.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: djm3452004 on May 10, 2019, 10:19:26 AM
Awesome, no problem on using a torque wrench.

And thanks for the responses derf, I appreciate it!

David
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: The Dark Side of Will on December 06, 2021, 05:21:09 PM
I stumbled across this purely by accident recently:

https://www.justdifferentials.com/Dana-35-Dodge-IFS-Front-Nitro-Stub-Axle-p/axd47067.htm

It's a 4340 output flange for the Dana 35 used in '97-'99 Dodge Dakotas. It has 27 splines, like the Eagle Dana 30 IFS.

(https://cdn3.volusion.com/ndyvj.kzbtr/v/vspfiles/photos/AXD47067-2.jpg?v-cache=1498046030)

(https://cdn3.volusion.com/ndyvj.kzbtr/v/vspfiles/photos/AXD47067-3.jpg?v-cache=1498046030)

I don't know if it will work in an Eagle diff or not, but might be an option.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: Softbuster on December 08, 2021, 05:26:29 AM
I wonder what the actual size difference is for the whole front axle assembly from a Dakota if it would be a viable swap?
Maybe even the front driveshaft too?  The CV axles probably wont work tho.
Title: Re: Overhauling Disco front diff: Parts list or references
Post by: TheBirdman on December 08, 2021, 08:54:51 AM
At one point I was researching to see if you could put a dakota front axle in an eagle, technically it is the same axle, but the main difference I found was the way the center section bolted on was different. As far as shafts being the same Id say its very likely that they are a direct fit.