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Old 12-25-2011, 12:13 PM   #1
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Unhappy powertrax lockright rear diff

Heres the problem .first off Its a 99 TJ 4.0
after getting the body mounts all replaced ,the owner ask me to look at the rear end .
he stated that a few weeks ago he had the rear axle seals replaced and the garage who preformed this .said they found spring fragments .
I did see eveidence of some wear on the ring gear.
the owner got a spring kit for the locker .Half the orginal springs were boke and the 2 missing
I installed all new springs ,and with the spring kit is a go, no-go gauage .well the no-go is where we are at.
actually can slip a .045 feeler gauge in also.
My question is could the axle seals be in wrong ,not seated properly or could there be something wrong with the rear end
I belive that the slop in the locker caused the springs to fail.
at $500+ for the locker I cannot let this slide out my garage .I want to make this right .

Ill post some pics later today .just looking for some insight

and it really dosent matter its a TJ its still a model 35 rear

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Old 12-25-2011, 12:37 PM   #2
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Umm, this would be better in the TJ section. But I am pretty sure the TJ was a D35 still. The D44 only came out later.

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Old 12-25-2011, 01:01 PM   #3
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Yea d 35 the same thing
I already told to can it and go 8.8. he cant afford that yet.the locker was installed by PO
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Old 12-25-2011, 08:38 PM   #4
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Can it be shimed behind the axle gears?
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Old 12-25-2011, 08:43 PM   #5
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yes I guess it could but the instructions say not needed If I had the origanal thrust washers I would try one .Ill be contacting the co in the Am.
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Old 12-27-2011, 11:11 PM   #6
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looks like Ill have to wait till next week for an answer from richmond gear. dose any ody know where I can get shims for the rear?
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Old 12-28-2011, 07:31 AM   #7
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looks like Ill have to wait till next week for an answer from richmond gear. dose any ody know where I can get shims for the rear?
So are you looking for a case shim kit or carrier main shims? I am confused as to where you are measuring to get the .045 feeler gauge in.
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Old 12-28-2011, 08:54 PM   #8
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I really dont know what Im look to do thats the whole problem.if this jeep was twisted in half I could fix that with no sweat.this is my first adventure in this area
ill give this a better shot of the description of what Im looking at
where the 2 halfs meet at the center pin is where they want to measure the gap . now with both sides engaged the no-go gauge fits loosely either way you check it , now with on side dis engaged it dosent fit at all
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Old 12-28-2011, 09:01 PM   #9
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heres the exploded view
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Old 12-28-2011, 09:42 PM   #10
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I was able to change out all the springs without complete removal.upon further study of the evploded view it dosent seem a shim could be used .but what do I know
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Old 12-29-2011, 08:05 AM   #11
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From the case exploded view, does it have thrust washers (#23). I would take it out and start from scratch with the install.


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Old 12-29-2011, 08:32 AM   #12
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Thrust washers ,powertrax says not to use them. I was thinking one could be added and adding this would tighten up the gap.
I will remove the whole unit ,and start over like you mentioned ,thanks for the response
chuck
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Old 12-29-2011, 08:35 AM   #13
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I read on another site that someone had a similar issue and took the couplers down .025 with a lathe to fit the washers in to get the proper fit. That's iffy to do. Good luck.
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Old 12-30-2011, 07:15 AM   #14
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Thank God I didnt have to chuck these up in lathe.
reinstalled and everthing is perfect,after seeing how this neat little locker works ,isee how it could be off.
Thanks for yor help.
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Old 12-30-2011, 07:30 AM   #15
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Sweet! Life moves forward.
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Old 12-30-2011, 09:31 AM   #16
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Thank God I didnt have to chuck these up in lathe.
reinstalled and everthing is perfect,after seeing how this neat little locker works ,isee how it could be off.
Thanks for yor help.
Nice, good job getting it figured out. Tell that guy to take it easy while wheeling since that Dana 35c's skinny axle shafts aren't really up to the differential being locked.
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Old 12-30-2011, 09:48 AM   #17
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yea ,I feel pretty stupid for not trying this before I posted I had a problem. going to find an 8.8 and change it out in a few weeks.
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Old 01-22-2012, 08:43 PM   #18
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Ok so last night the owner of the TJ calls a tells me. the right wheel is only one driving
tear the rear back down this morning and found the broken peices in the locker ,
but I found the po origanal problem. a leaking wheel cyl.he was told it was the wheel seals by his brother and had a shop fix the seals .in the shops possession they broke the 8 little springs off in the locker. then it comes to me to fix these this is when i imagine the real damage was done .so we put it back together and hes going to see if the parts are availble.

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