Ring and Pinion Gear Pattern Help

[NashvilleTJ]

OK - Here is the same setup, but with a few drops of oil mixed in with the pattern grease.

The marks at the top toe of the teeth are where I accidently rubbed my tension board.

 

[someguysjeep]

still appears slightly angular across the tooth but that does look better.

 

[Blackjack]

Two numbers on the box:

D60R-538R-OE

and

84677


What is a two cut gear?

https://www.differentials.com/two-cut-vs-five-cut-gears/ I thought Spicer included the appropriate documentation in the box but I also know that they have been slacking as of late.

 

[Wildman]

OK - Here is the same setup, but with a few drops of oil mixed in with the pattern grease.

View attachment 209876View attachment 209877

The marks at the top toe of the teeth are where I accidently rubbed my tension board.

I'm with Someguys that looks really good. Damn close and if it was mine I'd let use it. You did a great job at this. Is this your first time setting up gears?

https://www.differentials.com/two-cut-vs-five-cut-gears/ I thought Spicer included the appropriate documentation in the box but I also know that they have been slacking as of late.

That is some great information and I learned something new today... Makes for a great day.

 

[NashvilleTJ]

https://www.differentials.com/two-cut-vs-five-cut-gears/ I thought Spicer included the appropriate documentation in the box but I also know that they have been slacking as of late.

It's definitely faced hobbed (2 cut). I did know that term, and do have and was referring to that Dana spec sheet - but not the first page where it described the angled pattern. That may help - good call @Blackjack .

I reset the backlash to 6 thou - the bottom of the range - and took another pattern to see if it made a difference. I took some closer pics as well.

To me, it does not look deep enough. There is about 1/8" between the root and the bottom of the pattern, and it looks like the pattern is running off the crown of the tooth.

Does that mean I should be increasing the pinion depth?

 

[NashvilleTJ]

I'm with Someguys that looks really good. Damn close and if it was mine I'd let use it. You did a great job at this. Is this your first time setting up gears?

Yep - Definitely my first time. Thanks Rick.

 

[NashvilleTJ]

Just took a closer look at the original gears that I smoked - definitely the 5 cut / face milled. I actually had to clearance the housing just a bit to get the new gears to go in.

 

[Apparition]

Yep - Definitely my first time. Thanks Rick.

It’s good to see people trying this. It’s mostly a numbers game and I’m glad I can do it if needed.

I’ve not done enough to feel comfortable giving my opinion so I’ll leave that to those with more experience.

 

[Blackjack]

It's definitely faced hobbed (2 cut). I did know that term, and do have and was referring to that Dana spec sheet - but not the first page where it described the angled pattern. That may help - good call @Blackjack .

I reset the backlash to 6 thou - the bottom of the range - and took another pattern to see if it made a difference. I took some closer pics as well.

To me, it does not look deep enough. There is about 1/8" between the root and the bottom of the pattern, and it looks like the pattern is running off the crown of the tooth.

Does that mean I should be increasing the pinion depth?


View attachment 209891View attachment 209892View attachment 209893

Two cut gears can be a real pain the first couple times you do them. From the angled pattern and them calling for very low backlash (AAM gears call for 4 thou) can make you pull some hair out. I would try going deeper with the pinion as you do not want to have to pattern come off the top of the gear.

 

[someguysjeep]

ya i'm about to shut up because of not being familiar with that cut or angled pattern.......but i was gonna ask if less BL would pull that toe mark closer to center....and it does make sense to deepen it so it starts low and scrapes through the length of the tooth and not off the top like mentioned.

 

[Wildman]

I've never done those type of gears as far as I know.

Did you look at the formula on the sheet for how much backlash you should have?

 

[NashvilleTJ]

I've never done those type of gears as far as I know.

Did you look at the formula on the sheet for how much backlash you should have?

I did - the calculation for backlash results in 6-8 thou.

 

[NashvilleTJ]

Two cut gears can be a real pain the first couple times you do them. From the angled pattern and them calling for very low backlash (AAM gears call for 4 thou) can make you pull some hair out. I would try going deeper with the pinion as you do not want to have to pattern come off the top of the gear.

Thanks much, Blackjack. You coming up with the 2 cut definitely explained the pattern - and I now feel much better about it. But, now I'm starting over once again.

I think that the folks that suggested that I was too deep on the pinion may have been thrown off by that wanky angled pattern.

Now I think I'm back to making big moves to bracket the final result - so tomorrow I'll increase the pinion race shim stack by 10 thou - and see what it does.

Good thing I bought a big tube of pattern grease....

 

[Blackjack]

Thanks much, Blackjack. You coming up with the 2 cut definitely explained the pattern - and I now feel much better about it. But, now I'm starting over once again.

I think that the folks that suggested that I was too deep on the pinion may have been thrown off by that wanky angled pattern.

Now I think I'm back to making big moves to bracket the final result - so tomorrow I'll increase the pinion race shim stack by 10 thou - and see what it does.

Good thing I bought a big tube of pattern grease....

No problem. When I saw that you purchased OE gears it made sense. Biggest thing with 2 cut is to concentrate on getting the pattern centered root to crown and keep the backlash tight. They in a way "create" thier own pattern during break in.

 

[hosejockey61]

OK - Here is the same setup, but with a few drops of oil mixed in with the pattern grease.

View attachment 209876View attachment 209877

The marks at the top toe of the teeth are where I accidently rubbed my tension board.

Stop effing with that and button it up! Money.

 

[Claytone]

That latest pattern looks quite good. I forgot about the reverse cut coast/drive swap.
Keep messing with it till you’re happy, if it gets weird you can always go back to a previous spec.

 

[NashvilleTJ]

OK - I did two more setups today, going a bit deeper on the pinion depth, and this is the one that I think is best. It's hard to tell in the pics, but in the previous setups the patterns were definitely going off the top of the tooth. This time I think I've got the pattern fairly well centered between the root and the top. It is biased just a bit toward the toe. Backlash is 6 thou - the recommended range is 6-8 thou.

Good to go?

 

[Wildman]

Yes I think that looks really good. You are doing an awesome job for being your first time.

 

[Blackjack]

OK - I did two more setups today, going a bit deeper on the pinion depth, and this is the one that I think is best. It's hard to tell in the pics, but in the previous setups the patterns were definitely going off the top of the tooth. This time I think I've got the pattern fairly well centered between the root and the top. It is biased just a bit toward the toe. Backlash is 6 thou - the recommended range is 6-8 thou.

Good to go?

View attachment 210150

View attachment 210151

That is about as deep as you can go. You are just starting to get a sharp line on the root side of the pattern which is an indicator of being on the deep side. Definitely not coming off the crown and that is a good thing.

 

[Alex0413]

OK - I did two more setups today, going a bit deeper on the pinion depth, and this is the one that I think is best. It's hard to tell in the pics, but in the previous setups the patterns were definitely going off the top of the tooth. This time I think I've got the pattern fairly well centered between the root and the top. It is biased just a bit toward the toe. Backlash is 6 thou - the recommended range is 6-8 thou.

Good to go?

View attachment 210150

View attachment 210151

It's about time you tackled gears! lol This is looking better now that you got the angle out, but the pinion is a little too deep. The flat bottom and half moon is classic deep pinion. I'd remove a little pinion shim and rerun another pattern.