"Pacing myself" build

So basically, the gear setup is fubared. Not sure how that causes the vibes, so I'll have to leave that to someone that knows way more than me about gears.
Did you remove the carrier and ran it to see if that got rid of the vibes?
 
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Time to talk to @Indy or @Rob5589

Are you going to swap in another set of 4.56 or change it up?

My biggest fear right now is I re-gear it again and still get vibes. At that point, my wife would pretty much divorce me.
Gonna have a talk with my sup at work. He has some experience, so I could potentially get the labor for a cold pack and a pizza, but I did that last time, so once bitten, twice shy kind of feeling right now. Another option would be to take it to West Coast Differential in West Sac and have them gear it, or Hunter 4x4 in Roseville, or Cloak Works in Sac. I just don't trust anyone anymore. Certainly don't have anyone local I can trust.

I'll keep it at 4.56's. I don't have the coin to re-gear both axles, again. Gonna shop for some Revo gears, master kit, and a Detroit Truetrac. I ain't screwing with thick cut gears again.
 
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So basically, the gear setup is fubared. Not sure how that causes the vibes, so I'll have to leave that to someone that knows way more than me about gears.

Whoa. Damn! So the ring gear is warped? The ring gear spins at the same speed as the tires - so a warped ring gear or bad spots in the tooth during manufacturing or heat treating could definitely cause a vibration as the gears mesh in and out from near the warped spot.
 
So, the depth is far too deep; backlash too wide. It could be that the original installer ran the bl wide in an attempt to "cover up" the deep pinion depth. Opening up the bl can make the pinion depth appear less so, to a point.
Is this the cause of your vibration; I honestly cannot say. Been a long time but I do not recall dealing with vibration solely due to rear end set up. Most poor set ups result in noise and/or premature wear.
 
So, the depth is far too deep; backlash too wide. It could be that the original installer ran the bl wide in an attempt to "cover up" the deep pinion depth. Opening up the bl can make the pinion depth appear less so, to a point.
Is this the cause of your vibration; I honestly cannot say. Been a long time but I do not recall dealing with vibration solely due to rear end set up. Most poor set ups result in noise and/or premature wear.
If only I had time to pull the carrier yesterday and spin the input shaft, like Indy suggested, I'd know for sure. I don't really know what I'm looking at, but I didn't notice any wear of the gears, nor any metal in the gear oil. They have 40K on them. BTW, I do have a howl noise at 55mph under load. It changes pitch at coast.
Irregardless, the setup isn't right and needs to be replaced.
I did take video of the ds spinning to 75mph and it looked true.
 
If only I had time to pull the carrier yesterday and spin the input shaft, like Indy suggested, I'd know for sure. I don't really know what I'm looking at, but I didn't notice any wear of the gears, nor any metal in the gear oil. They have 40K on them. BTW, I do have a howl noise at 55mph under load. It changes pitch at coast.
Irregardless, the setup isn't right and needs to be replaced.
I did take video of the ds spinning to 75mph and it looked true.
The noise is most certainly from the improper set up. I wouldn't run it without the carrier and no oil for long or you'll have another issue; fried pinion bearings.
 
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The noise is most certainly from the improper set up. I wouldn't run it without the carrier and no oil for long or you'll have another issue; fried pinion bearings.

Agreed, I was only going to run it long enough to verify the vibes were gone, but it doesn't matter now. What are your thoughts on the Revolution REM gears, which claim no break in period?
 
So basically, the gear setup is fubared. Not sure how that causes the vibes, so I'll have to leave that to someone that knows way more than me about gears.
I hate it when people say it to me, so I’ll just say, “I’m glad you found it.” This will actually make me sleep better.
 
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If you regear it, you might as well get a locker. I know, but still
 
I hate it when people say it to me, so I’ll just say, “I’m glad you found it.” This will actually make me sleep better.

I hope this does it too. Just to be sure, if I do the re-gear, with the help of my sup, I'll spin it without the carrier just to make sure. At that point I could care less about damaging the pinion bearings, as they will be replaced.
 
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If you regear it, you might as well get a locker. I know, but still

Yes enabler, lol! While a locker would be nice, it'll add another$600+ to the cost, which I can't really afford as it is. I like the LSD in the rear. It's simple, and predictable. My wife occasionally drives the Jeep, so I need it to be predictable. A selectable locker would be nice, but it just adds to the complexity of the job. Heck, I'd keep the Traclok in there now if I didn't have to run a thick cut ring gear.
 
Yes enabler, lol! While a locker would be nice, it'll add another$600+ to the cost, which I can't really afford as it is. I like the LSD in the rear. It's simple, and predictable. My wife occasionally drives the Jeep, so I need it to be predictable. A selectable locker would be nice, but it just adds to the complexity of the job. Heck, I'd keep the Traclok in there now if I didn't have to run a thick cut ring gear.
Why the dislike of thick cut?
 
Why the dislike of thick cut?

Just fear it's a compromise in order to use my current carrier. Maybe a balance issue. It's all in my head at this point, so my decision not to use a thick cut gear is fear based, that's all. The Traclok works fine and all, but the clutches wear, whereas the TT is a one and done deal that I don't have to worry about.
 
My thoughts on break in are follow what the manu says. Personally, I just drive it as usual. When I did Tom's Rubicon we used the REM gears, and there was break in info with them. So, whatever that means.

WCD used to be the parts dept for Ring and Pinion Service, where I worked. I really couldn't comment as I have been away from them for many years.

I'd be willing to do it for you but the diff would have to be out. Killed my back rolling around my garage floor for 8 hrs doing Tom's Rubi. Too old for that now 🙄
 
My thoughts on break in are follow what the manu says. Personally, I just drive it as usual. When I did Tom's Rubicon we used the REM gears, and there was break in info with them. So, whatever that means.

WCD used to be the parts dept for Ring and Pinion Service, where I worked. I really couldn't comment as I have been away from them for many years.

I'd be willing to do it for you but the diff would have to be out. Killed my back rolling around my garage floor for 8 hrs doing Tom's Rubi. Too old for that now 🙄

Thanks for the offer, and your insight. I'll know more this week when I talk to my boss. I get what you're saying about the crawling around on the floor bit. If my boss helps me with it, it will be at work on a two post lift, off the floor, lol! My thoughts on having a shop do it is purely for a warranty, but if something goes wrong, I'd have to drive 2 hours to the shop to deal with it, so I'm torn right now as to do it with help, or have a shop do it. The good news is, my boss is super anal about the stuff he does, so he wouldn't care if we had to pull the carrier a dozen times until it was perfect, so that is comforting.