Novak Conversions Jeep Wrangler TJ engine mounts

A lesson learned—keep it light and nimble!

I'm in no hurry and while it's been a long time since I did a re-gear, the basics are the basics

- pre-load
- backlash
- pattern

Then adjust as necessary to get it done. It is tedious work, but no more so than other jobs. On the plus side, I finally got to use the clam shell bearing puller that has been sitting in a case for years unused. It's insane how easy these make pulling bearings!

20230520_104636-jpg.426313

View attachment 426893

Clamshell is the way.
 
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For anyone contemplating the cost of a good HP30 build, here you go. The basics of the build are the following:

- 30 spline Eaton e-locker
- 30 spline ECGS shafts
- Iron Rock lower control arm mounts
- Upper control arm JJs
- Revolution Gears
- BMB tie rod flip brackets

There are a few parts I bought extras on, but the total parts cost came in at around $2500. That cost went up a little, to $2600 witha few tools to make the job easier. Full disclosure, these costs only include items from the C's inward.

Part NamePart NumberNumber PurchasedCost EachCost TotalURL
Oil Slinger InnerYSPBF-0132$4.89$9.78https://www.amazon.com/dp/B0078U8TGW/?tag=wranglerorg-20
Oil Slinger OuterOMIX 16512.522$2.09$4.18https://www.amazon.com/dp/B000FPZVD6/?tag=wranglerorg-20
Oil Bearing BaffleOmix 16512.532$2.59$5.18
Dana 30 Master Install Kit W/e-lockerDana 30-MIK-ELOCK1$150.04$150.04https://eastcoastgearsupply.com/i-23993282-dana-30-master-install-kit-w-eaton-elocker.html
Eaton e-locker19819-0201$1,060.99$1,060.99https://www.4wheelparts.com/p/eaton...ing-differential-19819-020/_/R-BHXC-19819-020
Timken Eaton Carrier Setup Bearing RaceLM1029112$12.27$24.54https://www.drivetrainamerica.com/lm102911-timken-bearing/
Timken Eaton Carrier Setup BearingLM1029492$10.66$21.32https://www.drivetrainamerica.com/lm102949-timken-bearing/
Timken Outer Setup Pinion Bearing28721$23.27$23.27https://www.amazon.com/dp/B000BZAD0G/?tag=wranglerorg-20
Timken Outer Setup Pinion Bearing Race28201$16.96$16.96https://www.amazon.com/dp/B0071AZ13I/?tag=wranglerorg-20
Spicer Pinion Seal448951$7.48$7.48https://www.amazon.com/gp/product/B018OGH8PQ/?tag=wranglerorg-20
Spicer U-bolt Yoke2-4-8091X1$32.96$32.96https://www.amazon.com/gp/product/B018OGI9HW/?tag=wranglerorg-20
Spicer U-bolt Kit2-94-28X1$9.99$9.99https://www.amazon.com/gp/product/B000CKN6YA/?tag=wranglerorg-20
Revolution Gear Ring and PinionDana 30-410R1$204.57$204.57https://www.revolutiongear.com/product/dana_30_reverse_410_513_ring_and_pinion
ECGS 30 Spline Inner 27 Spline OuterAX-Dana 30-TJ-KIT-271$525.00$525.00https://eastcoastgearsupply.com/i-159906-dana-30-chromoly-axle-shaft-kit.html
Spicer Ball Joints706944X2$48.64$97.28https://www.amazon.com/gp/product/B007N6OHI0/?tag=wranglerorg-20
Spicer U-Joints (Pair)5-760X1$45.99$45.99https://www.amazon.com/gp/product/B00QAURWQO/?tag=wranglerorg-20
Iron Rock Universal Lower Control Arm Brackets TJ/LJ/XJ/MJ (Pair)10199$48.99$48.99https://www.ironrockoffroad.com/product/universal-lower-control-arm-brackets-tjljxjmj.html
Upper Control Arm JJs (7/16 greasable bolt) & Barnes Reinforcement PlateBought from forum member$100.00$100.00
Raised Swaybar Link Brackets and Gussets$78.00$78.00https://www.shop.blackmagicbrakes.c...rackets-and-Gussets-SWAYBAR-LINK-BRACKETS.htm
Tools Purchased:$59.84
Parts Purchased$2,526.36
Total Purchase$2,586.20
ToolsPart NumberNumber PurchasedCost EachCost TotalURL
1.5" Grinding Stone1 - 5 Piece Set$15.98$15.98https://www.amazon.com/dp/B0BB9Z3FN1/?tag=wranglerorg-20
1/4" Shank Flap Wheel Assortment1 - 20 Piece Set$12.98$12.98https://www.amazon.com/dp/B0B58DDH8X/?tag=wranglerorg-20
Inner Axle Seal Installation ToolV30911$30.88$30.88https://www.amazon.com/dp/B0BFQVRDWM/?tag=wranglerorg-20
Total$59.84
 
For anyone contemplating the cost of a good HP30 build, here you go. The basics of the build are the following:

- 30 spline Eaton e-locker
- 30 spline ECGS shafts
- Iron Rock lower control arm mounts
- Upper control arm JJs
- Revolution Gears
- BMB tie rod flip brackets

There are a few parts I bought extras on, but the total parts cost came in at around $2500. That cost went up a little, to $2600 witha few tools to make the job easier. Full disclosure, these costs only include items from the C's inward.

Part NamePart NumberNumber PurchasedCost EachCost TotalURL
Oil Slinger InnerYSPBF-0132$4.89$9.78https://www.amazon.com/dp/B0078U8TGW/?tag=wranglerorg-20
Oil Slinger OuterOMIX 16512.522$2.09$4.18https://www.amazon.com/dp/B000FPZVD6/?tag=wranglerorg-20
Oil Bearing BaffleOmix 16512.532$2.59$5.18
Dana 30 Master Install Kit W/e-lockerDana 30-MIK-ELOCK1$150.04$150.04https://eastcoastgearsupply.com/i-23993282-dana-30-master-install-kit-w-eaton-elocker.html
Eaton e-locker19819-0201$1,060.99$1,060.99https://www.4wheelparts.com/p/eaton...ing-differential-19819-020/_/R-BHXC-19819-020
Timken Eaton Carrier Setup Bearing RaceLM1029112$12.27$24.54https://www.drivetrainamerica.com/lm102911-timken-bearing/
Timken Eaton Carrier Setup BearingLM1029492$10.66$21.32https://www.drivetrainamerica.com/lm102949-timken-bearing/
Timken Outer Setup Pinion Bearing28721$23.27$23.27https://www.amazon.com/dp/B000BZAD0G/?tag=wranglerorg-20
Timken Outer Setup Pinion Bearing Race28201$16.96$16.96https://www.amazon.com/dp/B0071AZ13I/?tag=wranglerorg-20
Spicer Pinion Seal448951$7.48$7.48https://www.amazon.com/gp/product/B018OGH8PQ/?tag=wranglerorg-20
Spicer U-bolt Yoke2-4-8091X1$32.96$32.96https://www.amazon.com/gp/product/B018OGI9HW/?tag=wranglerorg-20
Spicer U-bolt Kit2-94-28X1$9.99$9.99https://www.amazon.com/gp/product/B000CKN6YA/?tag=wranglerorg-20
Revolution Gear Ring and PinionDana 30-410R1$204.57$204.57https://www.revolutiongear.com/product/dana_30_reverse_410_513_ring_and_pinion
ECGS 30 Spline Inner 27 Spline OuterAX-Dana 30-TJ-KIT-271$525.00$525.00https://eastcoastgearsupply.com/i-159906-dana-30-chromoly-axle-shaft-kit.html
Spicer Ball Joints706944X2$48.64$97.28https://www.amazon.com/gp/product/B007N6OHI0/?tag=wranglerorg-20
Spicer U-Joints (Pair)5-760X1$45.99$45.99https://www.amazon.com/gp/product/B00QAURWQO/?tag=wranglerorg-20
Iron Rock Universal Lower Control Arm Brackets TJ/LJ/XJ/MJ (Pair)10199$48.99$48.99https://www.ironrockoffroad.com/product/universal-lower-control-arm-brackets-tjljxjmj.html
Upper Control Arm JJs (7/16 greasable bolt) & Barnes Reinforcement PlateBought from forum member$100.00$100.00
Raised Swaybar Link Brackets and Gussets$78.00$78.00https://www.shop.blackmagicbrakes.c...rackets-and-Gussets-SWAYBAR-LINK-BRACKETS.htm
Tools Purchased:$59.84
Parts Purchased$2,526.36
Total Purchase$2,586.20
ToolsPart NumberNumber PurchasedCost EachCost TotalURL
1.5" Grinding Stone1 - 5 Piece Set$15.98$15.98https://www.amazon.com/dp/B0BB9Z3FN1/?tag=wranglerorg-20
1/4" Shank Flap Wheel Assortment1 - 20 Piece Set$12.98$12.98https://www.amazon.com/dp/B0B58DDH8X/?tag=wranglerorg-20
Inner Axle Seal Installation ToolV30911$30.88$30.88https://www.amazon.com/dp/B0BFQVRDWM/?tag=wranglerorg-20
Total$59.84

No price for the clamshell puller?
 
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I bought that several years ago from a buddy. The clamshell puller and case spreader for $100. ;)

Wow 👌

Clamshell puller alone is $300+ depending on which one you choose.
And then a quality case speader is $200+.
And I'll agree with app I like the case for the puller. Mine has a stand it all fits on.
 
Wow 👌

Clamshell puller alone is $300+ depending on which one you choose.
And then a quality case speader is $200+.
And I'll agree with app I like the case for the puller. Mine has a stand it all fits on.

I just did a quick search and found a puller for $120. For anyone else contemplating replacing carrier bearings, save yourself $120 in aggravation!

https://www.amazon.com/dp/B09RHXDMBP/?tag=wranglerorg-20
 
20230523_182137.jpg


20230523_182149.jpg


I just did a quick search and found a puller for $120. For anyone else contemplating replacing carrier bearings, save yourself $120 in aggravation!

https://www.amazon.com/dp/B09RHXDMBP/?tag=wranglerorg-20

Yes you can get them cheap now. Mine is a Yukon I think and it was close to $400 when I bought it in 2009.
And my case spreader was $250 I think.

20230523_182513.jpg


But I was doing a gear set about once a month for club members. So it paid for itself.
 
View attachment 427098

View attachment 427099



Yes you can get them cheap now. Mine is a Yukon I think and it was close to $400 when I bought it in 2009.
And my case spreader was $250 I think.

View attachment 427100

But I was doing a gear set about once a month for club members. So it paid for itself.

I ended up have to use the case spreader to get the stock carrier out. The wrench on the ring gear bolt trick didn't move it a fraction of an inch. Pry bar didn't work either, so out came the spreader, and out came the carrier!
 
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I bought one of these a while back. The quality seems good and the light weight is great.

DURATECH 24-inch Heavy Duty Aluminum Straight Pipe Wrench, Adjustable Plumbing Wrench, Drop Forged, Exceed GGG standard https://www.amazon.com/dp/B08G8T2B1S/?tag=wranglerorg-20

I ended up buying an aluminum 24 inch pipe wrench from Harbor freight. Was able to get the 25% discount, so the price ended up being $48. if it breaks, I’ll take it back and get a refund!
 
Novak Conversions Jeep Wrangler TJ engine mounts