Topic: D30R Hurting

[jagular7]

Was wheeling at KanRocks Frostbite event. Was not even close to being freezing weather, but alas, destroyed my XJ's D30R that was in the front of my TJ. The hill was a little muddy, so some momentum and tire spin was necessary to keep going up. I was 10' from an obstacle called as Zuk Squeeze. This is the result of tire spin hitting solid rock from a side impact. I didn't get off the gas fast enough.
Supposedly, the carrier case cracked at the point of the center pin. The center pin wallowed out the holes of the case and locker (lunchbox) before shearing.

Getting a stronger Detroit case locker and new gears. Adding some truss work. I'll be good to go.

This is the second 'inside' the diff housing issue I've had in 8 yrs wheeling the TJ. Several suggested to step up to a D44 since that might take care of the diff issue. Probably. But I've got RCVs for the D30 so cost wise, I'm a little in the hole. I'll just keep digging it for another 8 yrs.

[neale_rs]

Major damage!

[Bounty Hunter]

I'd sell the RCV's and upgrade to at least a d44.  A narrowed HP44 would be a good route to go.

[Jeffy]

Looks like the pinion backed out judging by the marks left on the carrier.  Then it got stuck in the carrier hole and broke the side out.  At that point the locker is able to spin and snapped the center shaft.

[jagular7]

Repaired with new r&p, Yukon Grizzly, and added some trimmed down JK inner sleeves to help strengthen the housing.
Picked up Friday night 630. Broke 1230 just after lunch on Sleepy Hollow in Flat Nasty, Jadwin, MO.

Broke a inner RCV shaft at the bearing collar tearing up the bearing, the leading bearing edge of the diff housing and the Grizzly locker. The pic of the locker is the bearing inner race. Shop had to cut bearing. Grizzly is getting a new left side portion of the case.

First set of v-set rocks -
<a href="https://www.youtube.com/v/BcXsQ784NXI" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">https://www.youtube.com/v/BcXsQ784NXI</a>

Climbing and squatting on last set. -
<a href="https://www.youtube.com/v/wypeek87EFQ" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">https://www.youtube.com/v/wypeek87EFQ</a>

Breaking off idle on last v-set rocks. -
<a href="https://www.youtube.com/v/kWYJEGXQDOk" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">https://www.youtube.com/v/kWYJEGXQDOk</a>

[jagular7]

Diff housing leading bearing edge is f'd as well. Bought another XJ front (D30R) as that's the cheapest option right now to get to wheeling. I could look to upgrade, RCV would provide 'credit' for trading mine up. (Didn't mention how much.) But anything other than a bolt in sharing hardware would be a greater cost, time down, etc. I've been wheeling this TJ the way it is since 2005. Haven't really changed much other than bolt-on and put in kind of upgrades.

The long side looks fine. Pics show what that leading bearing edge looks like. Last pic shows how its used.

[Jeffy]

Seems like a lot of money's going into those D30's.  I'd be looking to upgrade.  That broken axle shaft really did a number on everything.

[neale_rs]

The shaft was probably weakened from the last break.  Will RCV replace it for free?

[jagular7]

Yes, RCV (Poly Performance) has sent out a replacement inner short shaft. No issue there. Working with Yukon on the outer shell for replacement. Already replaced the housing with another.

During the rebuild to install Grizzly locker and new gear set, I had JK sleeves installed as a bonus. The shop drilled the amount of recommended holes and plug welded them. Lost out on that effort. They had noted how thin wall the JK tubes were to the TJ/XJs and that they had to 'hammer' the sleeves into the tubes. JK's, they just push.


Upgrade is a possibility, but for now, cheaper to replace and keep wheeling. I questioned RCV about credit for the shafts, they would (didn't say how much), for another application set. Talked about Toyota (FJ60) and they have a set for, get ready, under 700! for them. I had (sold it) a FJ62 front axle (comparable to Dana 60). I'm looking for another now. 9.25" ring, matching 4.88 available, dual piston caliper, vented rotors (14" IIRC), 30 spline shafts. Even though stock application is pass side drop, its symmetrically mounted in the housing so flipping the housing over is no big deal other than to rotate the knuckles and redrill vent n drain. Or TraiGear, RuffStuff, etc have pass drop housing for plug n play.
Then any upgrade has collateral damage to include steering, brakes, links, suspension, ds, frame mounts, and that's just for the front. Do front got to do rear to match, then tires/wheels.

[Bounty Hunter]

The locker and housing carnage looks WAY worse than what the actual break caused.  Surprised you broke with such low throttle and not a high-torque situation with the front end unloaded as it was.  I suspect something was going on with the locker before you got to this seemingly unassuming obstacle.

You can easily narrow a Ford HP44 and install one of many options for brackets to keep your stock suspension.  Same with a d60 if you decide to go the overbuilt route.

[sharpxmen]

looks like the shaft is straight with no relief machined at the spline end, not sure if what would have saved the shaft but it seems that it broke on the stress line there.

I remember the Alloy 30 splines i got were turned down to a smaller diameter in the middle between diff and u-joint, maybe to provide a "break line" there rather than at the ends.

but if it was related to tube alingment to the diff probably wouldn't have made a difference.

[stan98tj]

What size tires are you running and what gear ratio?
Also, do you think this would have had a different outcome if you had a full carrier locker in there ie: ARB or eaton or Detroit?
I have an HPD30 up front sleeved, full carrier Eaton locker and RCVs and plan on running 35s. My buddy ran this very axle on 35s and beat on it with a lunchbox locker and never had an issue.

[jagular7]

The last breakage was with JK sleeves, Grizzly locker and 4.88s installed into the 95 XJ front. The Grizzly is a full case locker. I've been wheeling with a TJ front D30 for 4 yrs and XJ front for the other 4 yrs.

Many commented thinking that placing any amount of torque without a way to move forward on that last rock, wouldn't matter if it was a D60 axle. Something was going to break.

Tire size is 35x12.5 on 15x7 rims. 4.88 gears. Lockright in rear 8.8.
Was Easy Locker (Detroit initial try at lunchbox) up front till last month. Swapped between TJ D30 and XJ D30.

[stan98tj]

The last breakage was with JK sleeves, Grizzly locker and 4.88s installed into the 95 XJ front. The Grizzly is a full case locker. I've been wheeling with a TJ front D30 for 4 yrs and XJ front for the other 4 yrs.

Many commented thinking that placing any amount of torque without a way to move forward on that last rock, wouldn't matter if it was a D60 axle. Something was going to break.

Tire size is 35x12.5 on 15x7 rims. 4.88 gears. Lockright in rear 8.8.
Was Easy Locker (Detroit initial try at lunchbox) up front till last month. Swapped between TJ D30 and XJ D30.

From all I've read and what I've seen with my buddy's Jeep, HPDana30s are pretty strong. I've seen a few posts advising not to push 4.88s and larger tires on that axle since it's at the capacity of the carrier, but I've seen just as many folks run just that very set up.