Last order of business is the Dana 30 HP re-gear. I got the pinion and ring in with pretty much originally shims. I’m not sure what I think about the first pattern. Anyone have input?

I need help determining why my gears (or bearings) are making this noise in the video I posted. It seems to happen when I change direction while turning the pinion gear. I made a setup race for the inner pinion bearing. Also setup bearings for the carrier.

My thoughts on the noise are either; the gears are too tight together has (.006-.007 backlash), there isn’t enough oil in the bearings, or the setup race and bearings lack of tolerance is causing play.

What does this noise sound like?! (please click the .mov link at the bottom; it is safe, it's the gears rotating with the noise)

 

The noise seems to go away when you continue rotating in one direction but once you start turning the opposite direction is when it starts with the clunking noise.
Also the clunking noise goes away when I put a little pressure on the ring gear while turning the pinion in either direction.

The rear axle re-gear https://www.cherokeeforum.com/f67/wh...5/#post3717923

 

While not an expert by any means in the diff department, is that some sort of limited slip or locker rig. They look like locking gear caps and a spring clutch mechanism...not stock at least what my insides look like. Might be the cause of your clunking

 

Yes that's a Torq locker; an automatic locker or what people call a lunchbox locker. It stays stationary in the carrier. The only time it moves is when the axles rotate at different speeds.
Thanks for the reply (those are rare now in days) I think it's definitely the ring and pinion. Pressing on the ring gear while turning, silences the clunking.

 

That does not sound like a rotating gear interface noise...also it is extremely clean and dry in there. How loud might that noise be if there was a cover on it and it was filled with gear oil. Do you feel anything odd when you rotate the pinion yoke. Is the locker addition new? I don't have one but do a search on lunchbox lockers...im pretty sure they all make some sort of klicking noise.....BUT I don't have any firsthand experience

 

The locker isn’t new it’s been in there for 8 months. They do make noise when turning since it does a ratcheting effect when tires are turning at different speeds; but not while going in the same direction. It’s not a locker noise. The carrier is “new” out of a Grand Cherokee that had factory 3.73 gears that I pulled to use to fit the 4.10s.

I think I found the issue. Without much effort was was able to remove the carrier from the housing by hand. I added a .004 shim to the left side (non-ring gear) and it tightened it up some that I had to use more pounding force to seat the bearing races. Torqued the caps down and the result was .007 backlash. Turned the pinion back and forth and clunking noise is gone. Now just need to make sure I get a decent pattern.

Here is after the added shim. I kinda like the coast side (top) but not too sure about the drive side (bottom).

 

I would run it like that. Its close enough. Dont forget to put that last bolt back in so the pin stays put!