Gear and Locker Install

[FINOCJ]

Starting some long term planning to learn how to install gears and lockers. If anyone is doing this on their own project and wants some free beer and pizza in exchange for having me around pushing tools, looking over your shoulder and learning... let me know. Thanks!

[PhillipG65]

What I have learned about installing lockers is that it is more tedious than difficult.
I am not going to be doing lockers but probably anti slip into the elephant
If you would like Jason the mechanic that was with me on our run in Barbour Forks, could do the job and most likely for the offer you made
Let me know how you feel about that idea and I'll talk to Jason about it, however, his wife can not find out he was with our group that day

[Java]

I've done all my own gears and lockers too, and if you're not changing the gear set it's actually pretty easy. If you want to DIY it I have this dial and base sitting in my garage since I did mine, yours to borrow if you want.

https://www.harborfreight.com/1-inch-travel-machinists-dial-indicator-623.html

https://www.harborfreight.com/multipositional-magnetic-base-with-fine-adjustment-5645.html

[FINOCJ]

I already have the HF dial and base from my transmission and TC rebuilds...wondering more about case spreader and how to set the axle races etc - can I just drive them in with brass drift or do I need a press? I was worried about some of this with the TC and trans rebuilds, but for the most part it wasn't an issue. Of course, the tedious nature of the gear set-up will be a pain - would be a lot easier if I have some sort of set-up bearings that can be slid on an off while fitting.

[Swank1975]

This is a job on my list for the future also. I want to re-gear and do a rear locker. I'm not thinking I'll do a front locker but that might change. :)

[FINOCJ]

Maybe we could have a forum tutorial session get-together - there is probably a few of us that would love to learn this and I am happy to help supply drink and food (and expense) to those that know what they are doing for their time and effort. Heck I'd even supply an axle to be used for demonstration purposes :)

[Java]

I did not need a case spreader, I used a drift and BFH for everything. Are you regearing?

In the first post of this thread is a video that is essentially the same experience I had:

http://www.frontrange4x4.com/forums/showthread.php?21816-How-to-Install-a-Detroit-TrueTrac

[FINOCJ]

I've done all my own gears and lockers too, and if you're not changing the gear set it's actually pretty easy. If you want to DIY it I have this dial and base sitting in my garage since I did mine, yours to borrow if you want.

https://www.harborfreight.com/1-inch-travel-machinists-dial-indicator-623.html

https://www.harborfreight.com/multipositional-magnetic-base-with-fine-adjustment-5645.html

I will be keeping the OEM 4.88s unless something is really damaged. Then I would most likely be looking for straight 4.88 replacement, but might consider 5.38s (and that would require re-working the front as well which I plan to leave open - manual steering). I was originally thinking I wouldn't need to remove the pinion, just the ring gear and case and that it should all fit back in with about the same shims and bearing load as it came it out with. But I should probably pull it all apart and replace bearings/races as well as seals. The pinion seal has begun seeping pretty good. I hate messing with stuff that ain't broke, but seems like if I am going in this far, should probably rebuild it all the way.

[dieseldoc]

The best thing I could teach you about doing a gear/carrier change.....have a pro do it.
Have someone that this is all the y do.....do the work.


It is tedious and frustrating as all hell!
Don't get me wrong done many from as small as toy 8" to drive pots on the drill rigs.
The big ones couldn't be done with out a over head crane.
The time it take to put it in check the pattern then pull it out shim change.
Do it again.....over and over.

[FINOCJ]

There are a lot of good reasons to get a professional shop to do it - but that wouldn't be fun and in the spirit of my old cj. Heck just owning a 47 year old jeep is tedious and frustrating. Drove it to work this morning - for some reason the back-up lights weren't working today. Add it to the horn that stopped functioning and a USB and 12V source I intend to add in for some electrical work that I keep procrastinating on - I find that way more tedious than anything else. I'd rather tear apart big mechanical pieces than eff with wiring. Ahh, just makes the reward of driving it that much better! I am still enjoying the fact it drove up Longwater rock on Sunday on the first try without any issues.

[dieseldoc]

Good for you with long water rock.
From the pics it look as there has been some work done to make the holes shallower.

Gear are not to much fun.
If all you are doing is a carrier change it's not to bad.
If I remember right that is what you are looking to do. Not a gear change.

[Spieg]

The best thing I could teach you about doing a gear/carrier change.....have a pro do it.
Have someone that this is all they do.....do the work.


Strongly agree with this. Differentials are more tricky than a transfer case. It takes some specialized tools and a lot of experience to do it right. Even a pro will tell you its hard to tell if they have things setup right. Given the expense of parts... I choose to let a pro take the financial risk.

[TJS86TOY]

I have a little different opinion. To me doing my own gears was more intimidating than anything else. With the rite tools it's actually fairly easy, just time consuming. Brandon is correct when he talked about the bearings being pulled on and off but with a clamshell puller it makes it so easy. I set my 60 up fairly quick and the pattern is great. I guess it all boils down to patience and self confidence.

[78bj40]

I can give you a hand if you like

[FINOCJ]

I have a little different opinion. To me doing my own gears was more intimidating than anything else. With the rite tools it's actually fairly easy, just time consuming. Brandon is correct when he talked about the bearings being pulled on and off but with a clamshell puller it makes it so easy. I set my 60 up fairly quick and the pattern is great. I guess it all boils down to patience and self confidence.

Hoping I can find a set-up bearings for it - D44 is pretty common. Those should slide on and off by hand.



If all you are doing is a carrier change it's not to bad.
If I remember right that is what you are looking to do. Not a gear change.

Yup - if all goes well, I should be able to leave the pinion in place and just change out the TracLoc case with the Eaton case. Have to move the ring gear from one to the other, and re-install shims on each side and check. No guarantee its will be the same, but it should be pretty close. Even if I have to pull the pinon and start from scratch, at least I will know exactly how it was properly set-up initially.

[FINOCJ]

The other good news is I cleaned-up the wiring connections a bit today on the back-up lights and got them working again, found the broken horn wire connection and its back to beeping, and even fixed the old cigarette lighter that has never worked. I have no need to light anything up, but if its going to be in the dash, it might as well work. Plus, it may well become a good 12V source for a USB charger.

[Swank1975]

Nice. I now have music in my rover after 4 new speakers were installed today. Ah luxury.

[FINOCJ]

I even found out from the ecj5 forum members that my cigarette lighter is OEM - or at least OEM replacement but in the correct dash location. I always assumed it was a PO addition - glad I got it working and didn't trash it for something new.

[FINOCJ]

Nice. I now have music in my rover after 4 new speakers were installed today. Ah luxury.

You mean you can hear something other than engine noise, soft top flap, wind noise, tire hum, Tera low gear spur teeth clack, D18 intermediate shaft roller bearing whine and whatever the noise of the day is that has you worried about the next failure? :lmao:

[dieseldoc]

I have a set if you need to
I don't need then you can have then.
I will leave them with There's.
Will send you. Pm after we pic them up from the shop.