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Old 04-15-2013, 10:36 AM   #1
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Dana 30 front end broken

I have a 93 YJ with a stock dana 30 front end, 4.11 gears and 33 tires. I was pulling out of my driveway and the front left tire locked up. Luckily it was on a dirt road and only about 10 MPH. I was able to roll the jeep forward but will not roll backwards. I was able to limp home by just creeping forward. Any ideas on what might be broke?
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Old 04-15-2013, 11:07 AM   #2
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Pull the diff cover and i bet the problem will be easy to spot

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Old 04-15-2013, 12:43 PM   #3
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and post a pic
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Old 04-15-2013, 04:25 PM   #4
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Pulled the diff cover and everything looks ok. It seamed like it might have been low on oil, only about a glass full, and what oil that was in there was pretty brown and watery. I just bought this jeep and I'm learning he wasn't very good at keeping up the maintenance.
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Old 04-15-2013, 04:33 PM   #5
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maybe its just the pic, but it almost looks like rust in there and alot of water moisture, and that fluid looks BAD, try to flush out as much of the old stuff as you can before refilling
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Old 04-15-2013, 04:43 PM   #6
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Might also check the left hub. If the carrier and gears look that bad I imagine that hub is pretty bad as well.
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Old 04-15-2013, 05:00 PM   #7
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Yes there is some moisture and some surface rust. The oil is more like mud. I'll pull the hubs off next and check them out. It will probably be a couple days before I can get to that. Thanks for the help so far.
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Old 04-15-2013, 08:10 PM   #8
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Wow that thing is toast. Clean with brake cleaner and hope the bearings arent toast from the moisture. Pinion looks possibly chewed as well. Personally I would get a new Dana 30 off CL for $150. That thing is a timebomb.

Check your rear asap.
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Old 04-21-2013, 07:22 AM   #9
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I pulled the front end apart and found that the pinion bearing had come apart and was seizing up when rotated backward. The carrier bearings were bad as well. So new bearings and seals will go in this week. The gears look good so I can reuse them. There were no shims for the carrier, is that normal? Any tips on replacing the carrier and pinion?
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Old 04-21-2013, 10:33 AM   #10
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Just take your time. If there weren't any shims, then you should re-install it as such. However, check your tolerances, and back lash. I can't remember if a D30 has a pinion crush sleeve or not, but you will want to replace that as well with a new one and torque your yoke nut back down and check back lash.

If you don't have a manual PM me and I can possibly get you a link to an online one.
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Old 04-21-2013, 12:14 PM   #11
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make sure it all gets sealed back up good too. and make sure the vent tube is in place and not letting water in.
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Old 04-21-2013, 01:37 PM   #12
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yeah, I've had my vent tube come out of the housing before and not realize it. She got filled with water really quickly.
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Old 04-22-2013, 03:46 PM   #13
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I glued my vent tube back in with black silicone after I realized how loose it was
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Old 04-23-2013, 06:38 PM   #14
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Hey guess what? No vent tube at all, just a big old hole. I guess that was where the problem started.
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Old 04-23-2013, 06:41 PM   #15
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thats highly likely, im sure you could find something to stick in there at the hardware store

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