Jeep rear end, ring and pinion troubleshooting

[MuleySniper]

Hey guys years back I broke the yoke on my CJ5 rear end, Dana 44. It slipped into the pumpkin.   Long story short my BIL and I tried doing the repair, he supposedly had knowledge doing gears. The pinion gear has a small chip in it, I was advised it wasn’t bad enough to replace. Anyways got her back together and obviously it’s wrong. It will operate in first gear but once you push the clutch in it locks up violently… I assume the backlash isn’t set correctly. Does anybody here do this kind of work or could recommend someone that does gears? Even suggestions, I’m fairly mechanical. It would be appreciated. It’s a nice jeep, I’ve put a lot of work into it but it just sits. I’d rather have it fully operable so I can either drive it or sell it. I’m in Gig Harbor, I have a flat bed to tow it or can remove the rear axel. I would also prefer to stay somewhat local within an hour or so of here. Thanks in advance

[follow maggie]

I had an axle rebuilt @ B&B Auto Repair in Bremerton & was happy with the results.  (360) 377-0682

[Turdle]

More than likely backlash. They have to be set up with a shim kit, and it helps to have some "set up bearings" they are old ones ground down a little smaller. You have to take the ring gear in and out, add or subtract shims to one side or the other, while checking a grease pattern on your gears. Its really a PITA, especially if your under the jeep doing it. I would suggest dropping the rear end and find a shop that can do it. Or youtube it and give it a try....  I can tell you jeeps are never ending project and you will be a better mechanic when done or you run outta money.

  J ust
  E mpty
  E very
  P ocket
                                       Good luck and enjoy !!   

[pd]

I seldom send my truck out for work, but I had to rebuild the rear differential last year.  I went to Rears & Gears in Port Orchard, and they were great.

[MuleySniper]

Thanks guys. Ya I learned just empt every pocket for Jeep years ago haha. The never ending project is part of the fun of owning a jeep. However over the years I’ve lost interest. I’ve had it down to the bare frame so I’m very familiar with it. The gears are a whole different demon tho and I prefer not messing with them myself ever again I’ll check out the mentioned shops, thanks again

[Caseknife]

That is some serious backlash, like maybe 1/4" or more.  Sounds more like the carrier is not being held in tight and shifting back and forth.  If backlash is off, usually get a whine on decel, not locking up.  Built many diffs while working for Chevy, but I'm out of that business and on the wrong side of the State

[MuleySniper]

Good to know. Maybe I’ll make one last effort, crack it open again and take a look.
Thanks

[timberghost72]

You could call or take it to Northridge 4x4 in Silverdale. I have bought quite a bit from them and they're a great local company and I believe they also work on vehicles.

https://www.northridge4x4.com/

[Magnum_Willys]

Gears are a pain - everything needs setup within .001 , you can diy but plan a day for it.   

[Woodchuck]

Dana type differentials are not the type you want to learn on without the help of someone who REALLY knows what they're doing. There are also some fairly specialized tools you should have so shims and new bearings are not destroyed in the process. 

[Magnum_Willys]

Took me a full weekend to change gears on my Willys front axle.  Of course I was stuffing Dana 70 gears in a Dana 60 housing so that was a bit more tedious!

[Matth]

Dana type differentials are not the type you want to learn on without the help of someone who REALLY knows what they're doing. There are also some fairly specialized tools you should have so shims and new bearings are not destroyed in the process. 

My first go around was with a 1961, 19 splined dana 44 that took i think 6 stabs.

[Tim in Wa.]

I seldom send my truck out for work, but I had to rebuild the rear differential last year.  I went to Rears & Gears in Port Orchard, and they were great.
[/quote
I second this suggestion

[MuleySniper]

Thanks for all the replies! I call Rears and Gears, they’re only 30 minutes away from me.

[Lumpy Taters]

I agree something is wrong.  If it locks up it should do it whenever there is load on it.  I know it sounds silly but watch a few You Tube videos and open it up.  If it wont move now you cant make it any worse.  I would really be interested to hear if the pinion nut is tight in the housing?   By the way the Jeep forums are full of very helpful people.    Randy's Ring and Pinion is a well known expert in the field I believe located in Everett.