I've broken my diff

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

I've done some upgrades on my KJ
265/75 R16
OME 2.5" lift
In the first test off-road, the alu diff housing, cracked.
It was not a very demanding uphill.
Someone has reinforced the diff case?
If i don't solve this problem, I'll never trust my jeep for off road fun again.

03black · **Posted:** Sun Feb 12, 2023 10:51 pm

Some on here found a steel collar to reinforce the area on the diff where yours cracked. Its a tight fit with the cross member but do a search on here, your mileage may very.

Do you have a locker up front? I have an ARB front locker and been off roading on level 6 trails and have complete faith in my jeep to do even more. The key is to be very ginger on the gas pedal especially with the diesel engines torque. The crack happens due to the ring gear "walking up" on the pinion gear when the one wheel that is spinning free all of a sudden catches grip, been talked a alot on here in the past when this place was really active.

JBA made a steel front diff in limited quantities and they are VERY hard to find. But now's a good time to find some 4:10's from the 4cyc gas liberty. Again those are also hard to find but doable in the junk yards.

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

Mine is a 3.7 V6
Mileage is about 130k (Kms)
Don't know the relation on the gears.
Here the video of the disaster
https://vimeo.com/manage/videos/798394867

03black · **Posted:** Tue Feb 14, 2023 9:17 pm

Gasser with the 3.7L came with 3:73 gears. Swapping to 4:10 will give you the power back and some MPG as well, all be it a small amount. The trans will also stop hunting and going in and out of overdrive.

Btw...video didnt load.

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

So it will be better to swap to 4:10?
Do you know what versions do they mount 4:10? so i can buy a 2nd hand one.
le5t's try if the video is accessible here: https://files.fm/u/p9tyj72z7

03black · **Posted:** Sat Feb 18, 2023 12:59 pm

Factory 4:10 gears came in the 2.4L gasser engine Liberty's. The front differentialis in the Liberty is a dana D30A. Dana D30 gears WILL NOT fit into into a D30A housing.

I forget what years the 2.4L engine came in the Liberty but you can Google it to make sure. You will need both the rear axle and front axle to be the same gear ratio.

Watching the video, i can see why you cracked the front diff. The gas pedal is not your friend when wheeling and you need to be going over obstacles slowly with the liberty. Small running bump starts (ie back up and get a running start with just enough power movement to "bump" up and over the obstacle) can be used if done gingerly.
When you were spinning the front tires, one of them "caught" the rocks and the pinion gear walked up the ring gear. The sudden stop in rotational force transfer the energy to the aluminium case and cracked it at its weakest point near the pinion gear. Search the forms here, its been talked about.

If you dont want to use the factory diff again, you can convert to a single front axle, but be warned its a lot of work, time and money to do the conversion.

WWDiesel · **Posted:** Sat Feb 18, 2023 1:51 pm

FYI:
Jeep Liberty First generation KJ (2002–2007)
PowerTech engines;
150 horsepower (110 kW) 2.4 L straight-4, discontinued in 2006
210 horsepower (160 kW) 3.7 L V6
Diesel engines;
2.8 L VM Motori turbo diesel (2005-2006 only)

03black · **Posted:** Sat Feb 18, 2023 4:48 pm

Thanks WW...i knew you would have answer

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

Thx for the answers!
Both gearing uses the same diff housing?
The reference number looks the same (50763 DANA ) for the 3.7 v6 and the 2.5 diesel.
So i can solve the aluminium housing problem whith the custom case and after change gears front and back axes.

The idea is to build a custom diff case, something like this:

03black · **Posted:** Fri Feb 24, 2023 10:14 pm

Yes, both the 3.7L, 2.8L, and 2.5L engines all used the same diff housing.

The front CV axles are different on the 3.7L and are NOT interchangeable with either the 2.8L or 2.5L

Many have tried to build a steel front diff housing but it never happened.

WWDiesel · **Posted:** Fri Feb 24, 2023 11:01 pm

juriola wrote:

Thx for the answers!
Both gearing uses the same diff housing?
The reference number looks the same (50763 DANA ) for the 3.7 v6 and the 2.5 diesel.
So i can solve the aluminium housing problem whith the custom case and after change gears front and back axes.
The idea is to build a custom diff case, something like this:

FYI: (05-06) models used the same style Jeep Liberty/Chrysler 8.25" corporate REAR axle assembly. But there was a difference between the ABS sensors location, 05's used a single center mounted sensor while the 06 models used two ABS sensors, one at each brake rotor.

Certain Gas powered Liberty's used different axle ratios depending on year model and engine size.
But as 03black stated; the front axle housing on the Jeep Liberty diesel used a Dana 30A aluminum axle housing while the 3.7 gas models used a completely different axle housing and they are NOT interchangeable.
JBA (Jeepin by AL) for a short period of time sold a totally steel axle housing to replace the Dana 30A. If you could luck up and locate one of these steel axle housings you will be very fortunate indeed.
I am not aware of any other steel housings available to replace the Dana 30A. If you find some, please share, there are probably several who would love to get their hands on one. :wink:

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

I've managed to take off the diff
The "pinion and crown" are damaged as well so i need to change them.
in the 2.5 diff I've bought there are a 41-10 (4:10) gears mine are 41-11 (3:73)
The idea is to install the 2.5 housing until we can build the steel one.
May I install the 41-10 in my car without changing nothing in the rear assembly?

WWDiesel · **Posted:** Tue Feb 28, 2023 1:13 pm

Sure, just leave the front driveshaft out so 4x4 can't be engaged/used.
Having 410's in front and 373 gears in rear would destroy the transfer case if you engaged the 4x4. :wink:

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

ok, done the front diff in 4.10. Now looking for a proper pinion to convert the rear. Any suggestions where to look for? I think some XJ had the Chrysler 8.25 in 4.10, isn't it?

03black · **Posted:** Sat Mar 04, 2023 10:45 pm

Good job! You'll notice a difference when you get the rear done. Be sure to disconnect the front drive shaft before you drive it till you get the rear to match the front.

Yes some Cherokee that had the chrysler 8.25 here in the states had 4:10 in them. But you can get the rear gear sets from aftermarket and have them professionally installed. Yukon gear is a good place order from.

WWDiesel · **Posted:** Sat Mar 04, 2023 10:50 pm

juriola wrote:

ok, done the front diff in 4.10. Now looking for a proper pinion to convert the rear. Any suggestions where to look for? I think some XJ had the Chrysler 8.25 in 4.10, isn't it?

If you are looking for a complete 8.25 rear axle assembly in a boneyard or salvage yard. Just don't forget the speed sensor requirements for ABS sensors for your year model.
I believe most 4 cylinder gas powered Liberty's came with the 410 ratio gears front and rear.

If you want to change just the ring and pinion gear in your existing rear axle housing assembly, you can find them new online at both the Mopar dealers and some aftermarket suppliers like RANDYS WorldWide, Inc: https://www.randysworldwide.com/ (formally Randy's Ring & Pininon)
This will require an installation kit, specialized tools, and knowledge of how to properly set up the correct ring and pinion gear mesh, backlash, and bearing preloads. :wink:

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

I found this. Is it?

https://www.amazon.com/-/es/gp/product/B000S6DRW4/ref=ewc_pr_img_1?smid=ATVPDKIKX0DER&language=en_US&th=1

WWDiesel · **Posted:** Mon Mar 06, 2023 1:38 pm

juriola wrote:

I found this. Is it?
https://www.amazon.com/-/es/gp/product/B000S6DRW4/ref=ewc_pr_img_1?smid=ATVPDKIKX0DER&language=en_US&th=1

Looks to be the right part number! Don't forget the installation kit. :wink:

And if you want a premium reusable differential cover gasket for your project, order a Lubelocker gasket.
LubeLocker Differential Gasket for Chrysler 8.25" Rear (Part No. LLR-C825)

juriola · **Joined:** Mon May 30, 2022 8:18 am **Posts:** 9

WWDiesel wrote:

juriola wrote:

I found this. Is it?
https://www.amazon.com/-/es/gp/product/B000S6DRW4/ref=ewc_pr_img_1?smid=ATVPDKIKX0DER&language=en_US&th=1

Looks to be the right part number! Don't forget the installation kit. :wink:

And if you want a premium reusable differential cover gasket for your project, order a Lubelocker gasket.
LubeLocker Differential Gasket for Chrysler 8.25" Rear (Part No. LLR-C825)

Thank you for the response!
well 25$ reusable gasket against 5$ one use. I will think about it

What else in the installation kit?

WWDiesel · **Posted:** Mon Mar 06, 2023 5:17 pm

juriola wrote:

Thank you for the response!
well 25$ reusable gasket against 5$ one use. I will think about it

What else in the installation kit?

Bearings, shims, new crush sleeve, bolts, contact pattern paint, etc...
USA Standard Gear (ZK C8.25-B) Master Overhaul Kit for Chrysler 8.25 Differential
https://www.amazon.com/USA-Standard-Gea ... 8OZS&psc=1

I've broken my diff

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