So I thought I was almost done re-gearing the Dana 30 on my 2001 TJ Sport. I upgraded the stock 3:07 to 4:56 gears, bought Revolution gears and a Yukon carrier (for 3.73 and UP). I did all the prior research and watched a lot of videos and came up with a step by step plan and got perfect preloads, backlash, and patterns-which took a lot of time -weeks! Bought extra shims, crush sleeves, made set up bearings and the whole nine yards. It was all going good, as the efforts were paying off with satisfaction with each subsequent step. Until tonight.
So I was putting the spider gears/axle drive gears back into the finished carrier and when I went to insert the retaining shaft through the carrier to capture said gears, it became apparent that the ring gear is clearly not going to allow it! I remember watching youTuber BFH showing an instance where a small amount of one tooth had to be ground away in order for the shaft to pass by, but I would have to remove almost all of one, and maybe the side of another! And 180 degrees it would definitely require two teeth! Now the answer is probably to remove the red lock-tited ring gear bolts and then pry off the new ring gear, install the spider gears then reattach the ring gear. But I thought that seemed weird, cause I never recall anyone doing the re-gearing with spider gears in place. But then most all the re-gearing videos I watched were also installing lockers. Oh, I took the front end off the Jeep to do this entire operation, so I was about to install this new carrier into the diff housing which is sitting across saw horses in my shop. I am open to constructive opinions and helpful advise! Thank You Folks!
So I was putting the spider gears/axle drive gears back into the finished carrier and when I went to insert the retaining shaft through the carrier to capture said gears, it became apparent that the ring gear is clearly not going to allow it! I remember watching youTuber BFH showing an instance where a small amount of one tooth had to be ground away in order for the shaft to pass by, but I would have to remove almost all of one, and maybe the side of another! And 180 degrees it would definitely require two teeth! Now the answer is probably to remove the red lock-tited ring gear bolts and then pry off the new ring gear, install the spider gears then reattach the ring gear. But I thought that seemed weird, cause I never recall anyone doing the re-gearing with spider gears in place. But then most all the re-gearing videos I watched were also installing lockers. Oh, I took the front end off the Jeep to do this entire operation, so I was about to install this new carrier into the diff housing which is sitting across saw horses in my shop. I am open to constructive opinions and helpful advise! Thank You Folks!
