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Author Topic: Odd noise coming from below the Jeep  (Read 7312 times)

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Offline jfrabat

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Re: Odd noise coming from below the Jeep
« Reply #30 on: July 25, 2013, 01:00:10 PM »
Well, we found the problem...  unfortunately, it is not pretty!  Broken ring and pinion on the D35...  Don't know how that happened, though, as I have not even gone wheeling!  Anyway, I have a spare one somewhere (from when I changed them thinking they were bad, when in fact it was the DS that time), so I'll throw those in.  Now I just got to find the rest of the hardware (bearings, etc.)...
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Offline Jeffy

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Re: Odd noise coming from below the Jeep
« Reply #31 on: July 25, 2013, 01:21:54 PM »
You probably weakened it when wheeling and it broke later on.  That happens a lot.
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Offline neale_rs

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Re: Odd noise coming from below the Jeep
« Reply #32 on: July 25, 2013, 01:38:06 PM »
Time to upgrade to a D44 or Ford 8.8!   .... and just sell the spare D35 ring gear.
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Offline jfrabat

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Re: Odd noise coming from below the Jeep
« Reply #33 on: July 25, 2013, 02:38:43 PM »
Quote from: neale_rs on July 25, 2013, 01:38:06 PM
Time to upgrade to a D44 or Ford 8.8!   .... and just sell the spare D35 ring gear.

That also means a new ARB locker, though...  Not exactly the right time for that kind of expenditure.
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'94 YJ 2.5L with 4" RE lift, Superwinch EPi9.0, FoMoCo e-Fan, SD30 and SD35 w/ARB-5.13, 165A alt., 33" BFG KM2 on 15" AR wheels, Sony sound system, Pavement Ends Hardtop, Hydroboost

Offline FourbangerYJ

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Re: Odd noise coming from below the Jeep
« Reply #34 on: July 25, 2013, 03:59:43 PM »
Mine broke on the street.
If you have a spare R&P get it back together then save up for a stronger set up. Then sell the D35.
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Offline neale_rs

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Re: Odd noise coming from below the Jeep
« Reply #35 on: July 25, 2013, 05:05:37 PM »
Quote from: jfrabat on July 25, 2013, 02:38:43 PM
That also means a new ARB locker, though...  Not exactly the right time for that kind of expenditure.

Now that you mention the ARB, here is a plan:  :pot:   Sell the D35 ARB, axle shafts, and gears.  That will get you more than enough $ for a Ford 8.8, which you can run with welded spider gears until you save up for another ARB.      I know it's not an easy choice, the downtime is also a factor for a daily driver.

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'95 YJ, 33 x 12.5 mud tires, RE 4.5 ED lift, Atlas 4 speed, rear D44, ARBs front and rear, 4.56 gears, 8000# winch

Offline jfrabat

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Re: Odd noise coming from below the Jeep
« Reply #36 on: July 25, 2013, 05:13:40 PM »
Quote from: neale_rs on July 25, 2013, 05:05:37 PM
Now that you mention the ARB, here is a plan:  :pot:   Sell the D35 ARB, axle shafts, and gears.  That will get you more than enough $ for a Ford 8.8, which you can run with welded spider gears until you save up for another ARB.      I know it's not an easy choice, the downtime is also a factor for a daily driver.

Keep in mind I live in Panama; D44 and 8.8 are not as common here as they are in the US, so they are not cheap.  Japanese pick ups rule the sales here, with the Toyota HiLux being by FAAAAAAR tue #1 seller.  I do plan at some point to swap in a complete toyota drivetrain, thpugh
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'94 YJ 2.5L with 4" RE lift, Superwinch EPi9.0, FoMoCo e-Fan, SD30 and SD35 w/ARB-5.13, 165A alt., 33" BFG KM2 on 15" AR wheels, Sony sound system, Pavement Ends Hardtop, Hydroboost

Offline FourbangerYJ

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Re: Odd noise coming from below the Jeep
« Reply #37 on: July 25, 2013, 06:48:59 PM »
The 2WD Toyota pick ups had 5 on 4.5 bolt pattern. Not sure what years or models. Width is pretty close too.
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Offline jfrabat

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Re: Odd noise coming from below the Jeep
« Reply #38 on: July 25, 2013, 07:24:01 PM »
Quote from: FourbangerYJ on July 25, 2013, 06:48:59 PM
The 2WD Toyota pick ups had 5 on 4.5 bolt pattern. Not sure what years or models. Width is pretty close too.

For now, I am just gonna fix it; I mean I DO have the R&P just laying around, so all I need are the other stuff... Certainly cheaper and faster than an axle swap at this time!
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'94 YJ 2.5L with 4" RE lift, Superwinch EPi9.0, FoMoCo e-Fan, SD30 and SD35 w/ARB-5.13, 165A alt., 33" BFG KM2 on 15" AR wheels, Sony sound system, Pavement Ends Hardtop, Hydroboost

Offline Jeffy

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Re: Odd noise coming from below the Jeep
« Reply #39 on: July 25, 2013, 08:05:47 PM »
How about a Toyota 8" from a Tacoma/HiLux?
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Offline FourbangerYJ

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Re: Odd noise coming from below the Jeep
« Reply #40 on: July 25, 2013, 08:48:07 PM »
Quote from: jfrabat on July 25, 2013, 07:24:01 PM
For now, I am just gonna fix it; I mean I DO have the R&P just laying around, so all I need are the other stuff... Certainly cheaper and faster than an axle swap at this time!

Like I said earlier. Fix it then look for a upgrade. Because it's only a matter of time before you will be fixing it again.  :uhoh: The Toyota stuff is way stronger than the D35!
Then sell your D35.
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Offline jfrabat

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Re: Odd noise coming from below the Jeep
« Reply #41 on: July 25, 2013, 09:47:47 PM »
Quote from: Jeffy on July 25, 2013, 08:05:47 PM
How about a Toyota 8" from a Tacoma/HiLux?

That could be; but for now, it's just getting fixed...
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'94 YJ 2.5L with 4" RE lift, Superwinch EPi9.0, FoMoCo e-Fan, SD30 and SD35 w/ARB-5.13, 165A alt., 33" BFG KM2 on 15" AR wheels, Sony sound system, Pavement Ends Hardtop, Hydroboost

Offline jfrabat

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Re: Odd noise coming from below the Jeep
« Reply #42 on: July 26, 2013, 09:14:52 AM »
They say a picture is worth a thousand words...  Well, here's a few thousand words, then:











Now, I still find it odd that the ring broke at the edge; the pinion is making contact in the center, so I just do not have an explanation for that one...  They told me it is likely that the locker was the cause for that type of damage, but I just don't buy it.  Anyway, the shop is the authorized ARB dealer in Panama, so they sent pictures to the ARB technician in Australia for his evaluation.  One thing is for sure, though...  Those magnets on the ARB diff cover sure come in handy!!!

So, what is YOUR opinion on the cause of the edge of the teeth breaking off?

Felipe

PS: Sorry about the crappy photos, but they came off my phone!
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'94 YJ 2.5L with 4" RE lift, Superwinch EPi9.0, FoMoCo e-Fan, SD30 and SD35 w/ARB-5.13, 165A alt., 33" BFG KM2 on 15" AR wheels, Sony sound system, Pavement Ends Hardtop, Hydroboost

Offline sharpxmen

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Re: Odd noise coming from below the Jeep
« Reply #43 on: July 26, 2013, 09:43:36 AM »
looks like bad setup contact pattern on the drive side, can you take a contact picture of the teeth that are not broken (that's what it looks to be the problem to me from the first picture you posted)? looks like the coast is the one that the wear pattern is centered but the drive side only contacted on the tip of the teeth where it broke, so i absolutely doubt the locker is the issue - if this is the case and you can see the wear only on the tip of the teeth then that's your answer, they broke because the load was applied just there and it was not distributed along the whole length of the tooth. There is also a matter of having the load spread between consequent teeth and if only the tip engages then it's all on that little piece which will eventually give. The pinion broke after due to the missing tips it was stepping on top of the ring. I would also ask them to check if the pinion bearings have play (no preload)

EDIT: isn't this the axle where they grinded off from the pinion as it contacted the locker? if it's the same shop then they did the setup incorrectly, should do it for free this time but the right way, i would ask to see the contact pattern before they close it off and also have them show you that the pinion bearings preload is correct
« Last Edit: July 26, 2013, 09:49:16 AM by sharpxmen »
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Offline grumpygy

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Re: Odd noise coming from below the Jeep
« Reply #44 on: July 26, 2013, 11:47:11 AM »
Quote
EDIT: isn't this the axle where they grinded off from the pinion as it contacted the locker? if it's the same shop then they did the setup incorrectly, should do it for free this time but the right way, i would ask to see the contact pattern before they close it off and also have them show you that the pinion bearings preload is correct
 


I was wondering the very same thing as I saw the photos.
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