Dana 25 Front Axle Overhaul

Just got the prussian blue. Did a pattern check. Can anybody help me interpret the pattern?

It's the same ring and pinion. Just new bearings and races. The pinion depth shims are .001 less than they were but I only had .011 and .008 shims to play with so that was about as close as I could get to how it was before.

Previous pinion depth shims: .033"
Current Pinion depth shims: .032"

Pinion yoke nut preload : 210 ft lbs
Pinion rotational torque reading: 28 inch lbs

Carrier Backlash: .007"
Ring Gear Runout: .002"

 

Why are you using different shims?

 

The old ones got mangled during removal of the inner pinion race. They were all .011. The new set I bought only had .008 shims

 

I am no expert but the pattern looks pretty good to me. I could live with that.

 

Yes, I used red locktite on the bolts.

 

On mine it was more than a thread locker, the machine shop doing the facing had it for other assemblies. If you have threads a high strength thread locker is fine.

 

The pattern is fine for a front diff... you're good to go.
It's not on the edge and almost centered!
Remember, this diff only turns ~10% of the time.
Any noise it creates will be overcome by all the other louder noises of your Jeep!

 

If you hear any noises you have the wrong exhaust lol

 

THAT'S GREAT NEWS! Thank you! I'm very excited to start putting things back together!

TRUTH. Still though, I can barely hear my exhaust over the sound of the transfer case most of the time!

 

Ok cool! I put in the order from Mcmaster Carr and should be getting the studs and counterbore in a couple days.

 

The counterbore is needed for spot-facing when using buttonhead bolts on the inside of the hub. For studs, these are simply threaded in from the outside.The studs have more thread depth than the original bolts.
-Donny

 

The buttonhead bolts are how the Dana30 is designed...might as well go all out and match the later model axle.

 

I don't think the problem with bolted-on spindles is the length of the bolts. Those can easily be matched to the available threads. But those available (read short) knuckle threads can be a problem.

 

Sorry I meant to say "Bolts" not "Studs" that I've ordered. I'm getting the aforementioned button head bolts from McMaster Carr:

 

If you have access to a lathe and a good carbide bit, you can just set the OD and crank right through all of the button heads without further adjustment.

 

Ok I've got a question about the carrier bearing cap bolts before putting it back together for the last time.... Per the Moses Ludel rebuilders manual, I had recently torqued these bolts to a uniform 80ft lbs during the setup.

I was just skimming the interweb watching CJ5 front axle rebuild videos and noticed that they all seemed to say 50 ft lbs for these bolts!

Checked the other two manuals I have....and they all seem to just say "for the front axle, please refer to the chapter about the rear axle"...

And then that chapter says 80ft lbs.

Just wondering if I'm missing something in regards to the dana 25? Why is it that a cursory google on the topic seems to say those bolts should be 50 lbs and then manuals all just lump them into being 80lbs/same as rear?

Also, what thread sealant should I be using in this application?
I have Permatex no.2, Permatex "gear oil" rtv, hylomar blue, and permatex 24200 blue on hand...

 

Also, If it IS 50 lbs.... should I be worried that I had them to 80 previously?

 

No. But just leave them at 80 unless you're taking them off to do the studs. Don't forget Loctite blue when you replace.

BTW, there's a little car show here in Silverado this coming Sunday the 15th, 11-4. There will be a few Willys, including me. I know it's kinda far, but I'd be remiss if I didn't mention it. I'll have beverages... Look up Silverado post office 92676 for directions.
Anyone else in SoCal more than Welcome. I'll have my blue and white Wagon, my buddies will have a wood grain Wagon, a yellow Jeepster and a yellow Wagon. Should be a nice day for a drive in the country.

 

I have been following this thread, and I find this fascinating. I've got a few extra knuckles from M38A1's in the shop and I think I'll do the stud conversion on them and when I do the front end on the 64 CJ5 upgrade the knuckles then. Also, will get a dual master cylinder and start fabbing up a bracket for it. Got the stuff for the 11 in brake conversion. I am constantly learning on this forum. Now, to just find time to do all of these great mods and finish my projects ... that's a whole other thing!

Dave

 

Working on my hubs right now. What did you use to clean up the bodies? I’ve sanded some on them, but still have some spots that aren’t cleaned up. Not trying to make them look new, just pretty (and functional).