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Gen 4 "Dana 30 " axle boots,bearings and seals replace

Bazz270

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Hi all

i am trying to fix front axle-shaft leaks. Ordered both sides shaft seals and bearings.
according to workshop manual, axle shaft outer shaft to diff circlips (one for each side ) should be replaced as well...

Cant find any evidence of this circlips...please help! thanks
 


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imp

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Hi all

i am trying to fix front axle-shaft leaks. Ordered both sides shaft seals and bearings.
according to workshop manual, axle shaft outer shaft to diff circlips (one for each side ) should be replaced as well...

Cant find any evidence of this circlips...please help! thanks
The circlip fits in a groove at the end of the axle shaft spline which enters the differential. It looks like this:

1628917790822.png


Made of spring steel, they engage an internal groove in the differential female spline. They "click" in or out when the axle is inserted or removed. It is best to replace them, though if not damaged, they often serve adequately if re-used. Important thing if replacing them is that they be sized correctly.
 




Bazz270

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Thank you

Just found c-clip for Dana 35 axle on rock auto.

According to Dana Spicer site:

Dana 30 and Dana 35 axles both have the same half shaft diameter and splines count.

Am i missing something or Dana 35 c-clip can fit?

Ford part number unfortunatly discontinued...

Update:

One of the halfshaft bearings discontinued too.according to Russian Gen4 forum ,Gen 3 both needle axle shaft bearings(instead of plastic gen 4 bushings)fits perfectly.

Also,found that cherokee liberty 07 have the same Dana 30 axle with 27 halfshaft splines.

Ordered two cherokee snap rings from summit:
Screenshot_20210814-114348_Gmail.jpg
 




Blackhawkxx

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It is best to replace them, though if not damaged, they often serve adequately if re-used. Important thing if replacing them is that they be sized correctly.
I guess that it is always best to replace things but I never have and most people I know don't bother unless they see something amiss.
 




Bazz270

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According to my experience and this forum threads


In many cases of reusing axle bushings or bearings and axle inner snap rings, seal leaks once again.

By the way,leaks appeared during front suspension rebuild,possibly after plastic bushings damaged (these half shaft have to be supported during suspension job)
It is really a lot of boring job to take half shafts out of the car twice :)

Plan B: If cherokee axle snap ring wont fit i will reuse the old ones too but i have to try cause they costs really cheap
 




Bazz270

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Update:

Not necessary to reuse or purchase separately C-clips since Oem TS211 boot kit containing all the hardware needed per one single CV boot side.

20210910_101503.jpg


Driver side halfshaft bearing and seal replaced:
20210910_083536.jpg
20210910_115627.jpg
 




Bazz270

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Driver side CV halfshaft needs to be adjusted to L=685mm total .inner Y joint snap ring needs to be replaced as well.

OTC tool used to tighten boot clamps.actually bolt-tight style tool better be used but this plier style should be ok too.
20210910_101501.jpg

20210910_104929.jpg



After halfshaft installed back,tighten new axle nut to 200Nm without wheel installed
20210911_182643.jpg
 




Bazz270

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Update:

Passenger side CV axle bearing and seal replace:
Remove halfshaft and axle shaft ,using prybar :
20210913_094839.jpg

20210912_165028.jpg


Remove axle shaft seal and plastic bushing using slide hammer:
20210912_170020.jpg


Since plastic passenger bushing discontinued ,ive replaced em with Ranger or Gen 3 needle bearing (the same dimensions as the plastic one) using regular balljoint installer sleeves.

20210913_094712.jpg

Replace axle shaft c-clip.check bearing race surfaces for wear:
20210913_095038.jpg

Use wood piece and 1kg hammer to lock this halfshaft in differential:double check it thru opened diff cover
20210913_135045.jpg


20210913_134950.jpg



Replace halfshaft boots and inner c-clip using ford TS211 kit:

20210913_134108.jpg


Replace lower balljoint if needed and reinstall all the suspension components acc workshop manual.dont forget loctite 638 for balljoint sleeve surfaces :
20210910_120452.jpg

20210913_095814.jpg
 




Bazz270

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Final step.axle cover rtv gasket replace.


After waiting a couple of hours (one hour acc. to workshop manual) for silicone axle cover gasket to cure,

Refill with fresh 80w90 liquid (ive purchased 75w90 by mistake bit it is not really matters)

Qty: approx 1.3L MAX or until u can feel axle liquid with your finger thru refill plug hole.

Do not overfill or axle seal leaks will be experienced once again.
20210915_095550.jpg
 




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