Overhauling Disco front diff: Parts list or references

[The Dark Side of Will]

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.

[The Dark Side of Will]

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

[The Dark Side of Will]

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




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




The typical condition of bearings in this unit




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




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

[eaglefreek]

Wow, that's pretty nasty in there. 

[The Dark Side of Will]

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.

[carnuck]

D30 on left but I think the D35 yoke may be the same as the tcase

[The Dark Side of Will]

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.

[carnuck]

I meant the D35/M15 yoke to the NPxxx cases.

[The Dark Side of Will]

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.

[The Dark Side of Will]

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.

[The Dark Side of Will]

From this:

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

To this:



via electrolytic rust removal.

From this:

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

To this:



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

[The Dark Side of Will]

double post

[The Dark Side of Will]

Got the intermediate shaft roller bearing out.

[carnuck]

where is that bearing? On the stub or the output shaft?

[The Dark Side of Will]

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.