Dana 30 and 44 ring and pinion install diy

[tigermuzza]

I'm in the process of changing my tj to 4.1, now I can find only bits and pieces on the Internet so i thought I'd do a write up as I go along to take the guess work out for everyone else. This is not a hard job, basic mechanic knowledge is needed and the right info. Don't be scared to tackle this job yourself cause the price and quality of work mechanics and even specialists offer is mostly crap. I've had too many bad experiences with mechanics to trust them anymore. I'm no expert but with patients and the right tools and knowledge it's a rewarding job. I've set up a hp dana 30 once before and the lp dana 30 is a little easier

So we will start off with what special tools are needed:

Torque wrench up to about 300nm ($100ish)
Dial indicator with magnetic base for backlash ($60ish)
Small torque wrench with a read out. 0-30nm for pinion preload ($50ish)
Diff spreader, I'll show ya how I made mine
Bearing press, optional cause it shouldn't cost much to get a shop to do it but ya can pick up a 12t press for around 200-300 bucks
Basic handtools

Remember these tools will come in handy more than once if ya haven't got them already

Parts are:

Ring and pinions with master install kits
An extra packet of shims just incase
Make sure ya get new seals with the kit and new rear wheel bearings
It's also a good time to do unis while the axles are out

[tigermuzza]

I forgot new carriers too

Today I striped the from end of hubs and brakes and removed the axles, in the pic you can see the difference in the carriers, the flange is thinner on the 3.73 and up

[Tallpieman]

Good right up mate... do you plan on using setup carrier bearings?
Are you adding lockers?

[tigermuzza]

The next is bolting the crown gear onto the carrier, this one went on without any heat but if it doesn't go on put the crown gear in the oven at 150 degrees and it should slide on, if its still to tight you can always put the carrier in the freezer also, put in a vice and knip up the bolts and tighten to 110nm, remember to do them up in a star pattern. It's probably a good idea to wait till the crown and carrier are at room temp before torqued

Notice why the flange is thinner, the 4.1 crown is thicker than the old 3.07

http://i1208.photobucket.com/albums/...zza/null-1.jpg

[tigermuzza]

Sorry I'm having trouble adding photos, here's the new attachment

I'm adding a sparten locker to the rear and no setup bearings, I'll press the new bearings on the carrier and put the shims on the outside of the bearings to set it up then pull the bearings and put them in the right spot

I see a lot of people use there old bearings to set up, die grinding the inside to make them slip on but I think there would be too much play in the old bearings to do that, we're talking getting the measurements to a thousands of an inch. Ya can buy proper set up bearings for around 80 bucks I think but I wont bother

[Tallpieman]

Originally Posted by tigermuzza

Notice why the flange is thinner, the 4.1 crown is thicker than the old 3.07

I think this is because the pinion head is smaller

[tigermuzza]

Originally Posted by Tallpieman

I think this is because the pinion head is smaller

Yeah probably a bit of both