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

[Bazz270]

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

 

[imp]

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:

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]

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:

 

[Blackhawkxx]

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]

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]

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.

Driver side halfshaft bearing and seal replaced:

 

[Bazz270]

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.

After halfshaft installed back,tighten new axle nut to 200Nm without wheel installed

 

[Bazz270]

Update:

Passenger side CV axle bearing and seal replace:
Remove halfshaft and axle shaft ,using prybar :

Remove axle shaft seal and plastic bushing using slide hammer:

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.

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

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

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

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

 

[Bazz270]

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.

 

[Bazz270]

The axle started to make harsh driveline clunks and developed pinion both radial and axle play.Ended with full axle rebuild with Yukon Dana 30 Super rebuild kit p/n 14222 (both ring and pinion bearings ,new seals and the crushwasher) plus OEM bushings replaced ( they are two upper the same and the lower is the bigger one.the top bushings was discontinued so ive used similar size Ranger bushing

1L2Z-3A443-AA bottom -one​

F67Z-3A443-AA -top- two​

the axle setup is pretty similar to any other Dana 30 axle (Dana 30 Super was factory installed on 4 Gen Explorers and old Jeep liberty only - Dana 30 Super it is actually a regular Dana 30 plus Dana 35 long pinion).

keep the original carrier shims for the initial setup, then change the backlash and the pinion depth if needed. ive left the initial pinion depth as is and changed the backlash (twice) only when dial indicator read was 0.23mm (0.25 is the maximum dial indicator backlash).


Yukon manual says at reused gears to look at the coast side only but ive looked at them both

pinion preload at old reused gear is 2.4 to 3.5 N.m.
carrier caps torque are 60-65 N.m
use high torque impact wrench (Minimum 500N.m until you get the proper reading of approx 2.4 N.m of the pinion rotation effort )to set a crush washer-controlled pinion preload (do not try to measure the preload until the pinion axial play are zero)

special tools needed :

1.29mm pinion nut impact socket
2.workshop press 10Ton plus truck size bushing installer kit
3.bearing removal tool (the big one)
4.dial indicator plus magnetic base
5. pinion preload torque tool

Yukon 14222 kit contains Timken ring and pinion bearings , Yukon axle oil seals, shim kit, paint, threadlocker, new pinion nut and two crush sleeve.

pinion seal and the axle shaft bearings needs to be purchased separately (Timken changed the seal design a bit but it isnt matters )