BlueBalls

As the title states I'm in the process of setting up my D30 (2001 Jeep Cherokee XJ). Lol! front end!

These are the original to this XJ (Ring, Carrier, Pinion). So the actual values for these items are static (unchanged).
I've made setup bearings.(yes I verified them by measuring with a caliper and they do match the New Timken Master rebuild ones).
Inner pinion setup bearing. RGS (Ring Gear Side) bearing and a NRGS (Non Ring Gear Side) bearing.
I measured with my dial indicator at several points and came up with a overall starting point of (0.075) for total space (without pinion installed) at back of carrier behind RGS
I measured with pinion installed and came up with a starting number of (0.042) RGS.
I measured (with a caliper) all my original shim pack and that value was (0.102).
I temporarily installed the pinion (NO seal, crush sleeve at this point) and placed the starting values in...
0.042 at RGS
0.035 at NRGS

Of course it would have been sublime to get the measurement dead on first try (yea right?) but it took many, many more attempts to actually get close to the real numbers.
Actual Numbers:
0.029 at RGS
0.064 at NRGS

Here is where I seem to get the best gear tooth pattern and I get a backlash value between .005-.010

Where is my question?
Does this seem like correct values to the peeps who have set up gears before?
Do the values seem in the ball park?
Is the carrier suppose to be a bit snug (aka tight) when turned by hand?
Does it seem plausible that the original setup had the extra 0.009 shims but not my setup? (I'm using brand new Timken setup shims + a few of the original)
Will this cause to much slop?
If I try to use the remaining 0.009 its just way to tight?


I feel that I've got it in the ball park but I've only ever setup one other axle ...... the D35 on the rear of this XJ..

00t444e

If the pattern looks good, the backlash is correct, the carrier is in tight and your pinion preload is correct your good to go, don't get caught up on shim thickness numbers.

4.3L XJ

. 05 to .010 is right in there. Most factory set ups are right at .008. In other words it should just barely rattle when you wiggle the ring gear back and forth

BlueBalls

Thanks...Keep it coming lol.
I'm just nervous that if it is to tight it will cause damage and of course to loose the exact same.
Man I must have spent at least 7hrs. just measuring, verifying and re-measuring and checking and still am not 100% sure I've got it exactly right.
This has been an absolute pita.
The rear was difficult in other ways but this is really ugh!

I'm at that point where I would like to put on the final bearings and just be done but still cautious.

The ring gear pattern is in the middle third of the tooth and slightly toe (ring gear inside diameter) as I can not get anymore adjustment out of the pinion. Which actually looks pretty good.
The heel (ring gear outside diameter) is not obtainable because my case is already at zero shims on the inner pinion race as it was from the factory.

So, do I just run with it?
By the way I did find a pic that sorta resembles my pattern but not quite.



Mines a little fuller but similar.

Dave51

IMO you have something askew there. If

You're out of spec as allowable variation is 0.002 in.

"A bit snug" is rather subjective, but I'm going to go with "no".

I believe carrier preload should be about 0.015 in. so maybe you're just a bit (0.003 in.) too tight. How difficult was it to pound the carrier back in? I think the correct value is "sorta difficult".

Double check the backlash and assembly.

BlueBalls

So, started the morning early. Tore it all back out and gave it another go. Started to sleet, rain hard so came in the house.
Probably got 4 hours in though. My values are much better today as is the back lash but I'm going to move .004 over from RGS to NRGS and recheck. At this point I have lash of .006 and pre load at acceptable range.
I'm hoping this slight adjustment will provide a sweet spot of .007 to .009
RGS .045
NRGS .057
Back lash .006

My next test (tomorrow) will be
RGS .041
NRGS .061
Back lash tbd

​​

Dave51

.006 IS the sweet spot:

Carrier doesn't bind, and the .006 is good all around the ring?

BlueBalls

Now you tell me...haha

I kept tightening up on the tolerance trying to narrow in to .007 to.008... I worked in the freezing cold today to make sure I got that bad boy in that all so talked about sweet spot. Which I thought was that range.
I thought .006 should have been good but now I'm dialed in to .007 to .0085 or at least that area. There is of course variance for run out on the old ring gear carrier.

The problem I'm now facing is this crazy crush sleeve. I JUST CANT crush it lol. I damn near tore my breaker bar in two. I've used that and one other half inch socket wrench for damn near every other heavy hitting job. I'm talking freeing stuck hub bolts in rust belt USA! This bad boy is just not moving. Not even my half inch Earthquake gun can get the crush to start. That bad boy is a heavy hitter all brute pneumatic.

By the way I purchased one of those handy yoke plates that have the socket box cut right into them so NO plumbers wrench need.

Dave51

Garage jack handle on the breaker bar.

Do you still have the receipt for the breaker bar?

BTW how much play in the spiders?

Dave51

Yeah some, but IMO you're getting pretty close:



Is the axle tube true?

BlueBalls

Well finally put it all back together yesterday.
RGS .0475
NRGS .053
Backlash .008
Pinion preload .012 - .014 in/lb measured with bar type
Carrier + pinion .027 - .029 in/lb measured with bar type

Way to tired to test drive so just left it. While I was at it put on a brand new front oem style front driveshaft.
God I hope this fixes the issue...

​​And I red loctited the **** out of the pinion nut. Everything is now new, save for the ring/pinion themselves.

BlueBalls

Was able to get it off the jack stands and drive it in reverse down the driveway to park it lol!
That is a start. No noise at least in the street moving it to the curb to park.
Crossing my fingers because it needs to be gassed and then tested. It was a few weeks ago when all this cr@p started... haha.

BlueBalls

Took it up to 40-45mph and very smooth. 2wd only.
A bit gun shy to try 4x4 yet. Sometimes ignorance is bliss lol.
Tonight it was pouring so great time to attempt 4x4. Better than i thought. At least seems to be.
Jury is still out. Thankfully no heavy grinder sounds.
Still a bit of weirdo chop, slop. I'm guessing ball joints?
​​​​​​​

4.3L XJ

I hear ya. I am the same on major mods

BlueBalls

Drove it yesterday and was pleased. Seemed okay.