KJ Dana 30a Fracture Site

Fulltimer · **Posted:** Sun Dec 28, 2008 6:16 pm

I hope this picture shows what I want it to. In looking at a couple of busted 30a's it seems they all break in the same place. This is a picture of a good Dana 30a and I scratched up where they seem to break. Has anyone had one break somewhere else?

Terry

EDIT:
Marked with marker.

tommudd · **Posted:** Sun Dec 28, 2008 6:28 pm

Thats pretty much in the right area I would say

Diggerfreek · **Posted:** Sun Dec 28, 2008 6:33 pm

yep, looks right to me

jeepkj02 · **Posted:** Sun Dec 28, 2008 6:58 pm

It would be a good idea to weld in some gussets to strengthen the area.

Hood297 · **Posted:** Sun Dec 28, 2008 7:09 pm

jeepkj02 wrote:

It would be a good idea to weld in some gussets to strengthen the area.

Its a real art to weld aluminum.

KJ04 · **Posted:** Sun Dec 28, 2008 7:33 pm

The line you have is to straight, both of my breaks have angled upwards.
You can see at the pinon area where the colar held that together on the 2 nd. one. On the 1 st. housing without a colar, that whole area was broken out.

Fulltimer · **Posted:** Sun Dec 28, 2008 8:49 pm

KJ04 wrote:

The line you have is to straight, both of my breaks have angled upwards.
You can see at the pinon area where the colar held that together on the 2 nd. one. On the 1 st. housing without a colar, that whole area was broken out.

Hmmmm, nice picture! I wish I could see it. Try again?

Terry

Fulltimer · **Posted:** Sun Dec 28, 2008 8:55 pm

So with a collar it breaks a little differently. What I am wondering is if the area that breaks can somehow be reinforced, would it just break somewhere else? It seems like it might.

Terry

Diggerfreek · **Posted:** Sun Dec 28, 2008 8:59 pm

it would seem as the casting is flawed or the composition of the metal is just to weak

sleeve84028 · **Posted:** Sun Dec 28, 2008 9:17 pm

I know it's expensive and would add weight, but a steel housing would really fix that problem.

XR · **Posted:** Sun Dec 28, 2008 10:31 pm

Putting a band aid on a sucking chest wound.The only fix is elimination of the offending part.

corwyyn · **Posted:** Sun Dec 28, 2008 11:15 pm

Fulltimer wrote:

KJ04 wrote:

The line you have is to straight, both of my breaks have angled upwards.
You can see at the pinon area where the colar held that together on the 2 nd. one. On the 1 st. housing without a colar, that whole area was broken out.

Hmmmm, nice picture! I wish I could see it. Try again?

Terry

I think this is the picture he was trying to post:

And there are some good pics of another blown diff in a thread in the downunder section.

Diggerfreek · **Posted:** Sun Dec 28, 2008 11:22 pm

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ChileanKJ · **Posted:** Mon Dec 29, 2008 9:16 am

From the pictures seems that the side support has the fault for the failures instead of give support, it makes lateral force and help the breaks. In the KK this support went to under and center of the differential, I think some fork can be made to put the the KK differential instead of the KJ, but I don't have one to take measures (and I will look funny if some one see me under his KK with a measuring tape) looks like the front 3 point support is the same as the KJ, and the rear needs to cut and put a new support. But all this risks only if whe can put at least 33 tires.

Fulltimer · **Posted:** Mon Dec 29, 2008 12:31 pm

ChileanKJ: Your right! Probably not a good idea to just walk up to someone's KK and crawl under it. Good way to get hurt! :lol:

I have been thinking the same thing about some kind of adapter.

Terry

Sean150 · **Posted:** Mon Dec 29, 2008 12:51 pm

If I remember right Jerbacher's broke pretty much the same with a large piece that fell off when it shattered. Its too bad that Dana doesn't offer something similar made out of steel that we could all get as a replacement for the faulty 30s that came stock.

Fulltimer · **Posted:** Mon Dec 29, 2008 2:38 pm

Sean150 wrote:

If I remember right Jerbacher's broke pretty much the same with a large piece that fell off when it shattered. Its too bad that Dana doesn't offer something similar made out of steel that we could all get as a replacement for the faulty 30s that came stock.

It seems they all break pretty much in the same place, unless there is a collar on it.

Terry

tommudd · **Posted:** Mon Dec 29, 2008 2:46 pm

From all that I have seen pictures of (and jerbachers up close and personal) they all pretty much start in the same area, some may split out extra depending on the stress they have at the time but ...thats the general area for sure. I think the collar may hold it togerther some and let you get out of the way maybe but thats about it. The collar is only a band aid

XC204 · **Posted:** Mon Dec 29, 2008 3:13 pm

Looks like a support could be fabricated to uses the existing mounting holes for the front and both side mounts that collar the pinion bearing area and braces over to the passenger and driver side mounts. Someone with a broken one could do this easily as long as the parts could be pasted together enough to do the mock up or send it to someone who can. Ill try to make a rough dwg of what Im talking about this week.

ChileanKJ · **Posted:** Mon Dec 29, 2008 3:24 pm

I will try to find the guys who did this:

KJ Dana 30a Fracture Site

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