dan10101

I'm doing a Truetrac install with Yukon 4.56 Gears on a 1998 D30.
The Yukon gears and Yukon bearing kit came with the jeep in a box, ( I added the truetrac). The first problem is the outer pinion bearing in the overhaul kit is too small for the housing. The Race I have is 02820. Near as I can determine the Bearing should be 02872. (mine is shredded so I can't tell you what it is).

Note: all the other bearings/seals etc in the kit are correct.

From another Jeeper website:
XJ CJ PINION Diameter @ outer bearing 1.125" ; 26 Spline
CJ,XJ Outer Pinion Bearing: (Set50) Koyo 02872 ; Race Koyo 02820

The next problem is that the 02872 bearing won't slide easily on the pinion. Everything I see says it should not be a press fit. Do I have that wrong?

The 3rd problem is that I cant find a decent video showing the install process. Can someone point me to a video or set of instructions.

Yes, I have problems. But I'm not a total idiot, (although at times I feel like one). I managed to complete the rear 8.25 install without any major issues.

Carnage picture for attention, and to feel sorry for me.
https://www.cherokeeforum.com/attach...1&d=1506464387

dan10101

So apparently I'm not alone.
https://www.cherokeeforum.com/f2/str...bearing-23775/

That's one question.

But I still need to know if the outer pinion bearing is a press fit or slides on.

Also, does anyone know of a good D30 rebuild video?

Thanks,
Dan

dan10101

I don't know what it is about my posts that get no response. Less wordy, less needy, do I sound like a know it all? I'd be curious, (pm me if you like). I'd like to word them better the next time.

well, for future searches...
Anyway, A quick call to Yukon confirmed my questions.
I had the wrong kit. (for a Volvo) Well, it was free and most of the pieces work.
The 02820/02872 race/bearing combo is the correct for my 98.
As the tech described, it is an interference fit. So, not a press fit, not a slide on.
So now it's time to get this thing done...

Greenz

You had good questions. I had no good answer.

Youtube is full of Dana 30 regear videos. I figured you had already explored those. I watched many of them and still took my jeep into a pro shop.

Good thing I did. Had a noise in the front after new gears were installed. Shop found the pinion preload was not correct so they installed a new crush sleeve and sent me on my way. That took care of the whirring noise but not the howling. Took it back and now they are replacing the gears again. They said is was a bad set. I don't understand that but if I had installed them and got those noises, I would have been very discouraged. It's a race/Jeep shop been around 40+ years very reputable.

Good luck!

dan10101

I seem to find all the hard questions. And, I'm my own worse customer. But this is something I wanted to try over many years of wrenching. So I'm giving it a go. It's a bit scary when the pros have trouble with these installs.

I think I'm pretty close, still trying to get the pattern as close as I can. I've already had it out 7 times, what's a couple more.

Where bouts in Oregon? I'm outside of Medford.

Outlaw Star

Well, glad you got the answers you needed, I had nothing on my end except "wrong kit".

dan10101

Happy to entertain!

I'm getting closer. How does this pattern look?

Drive side
https://www.cherokeeforum.com/attach...1&d=1506632306

Coast
I uploaded the wrong picture for the coast side.

dan10101

Let's see if this is the right one. (I have lots... )

Coast side
https://www.cherokeeforum.com/attach...1&d=1506632971

Greenz

You're doing good on the install. I would have had to buy the specialty tools I thought I would most likely never use again. Between the XJ and my motorcycles, shop space is beyond a premium. I guess I'm luckier than some to have any space but it is getting ridiculous all my crap.

I'm in Hillsboro. Have family down in Glendale with lots of private property, both sides of I5. My nephew wheels the crap out of anything up in those hills.

dan10101

I did buy a cheap Harbor Freight press for this project. I had to think carefully where I was going to put it in the already very cramped shop.

It's nice to have a place to play. I have a couple acres of hillside that is mine to make tracks. Can't wait to get this diff done so I can take a "test drive", well, after a break-in...