Front Diff Reinforcement Collar

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

Here is my band-aid fix. Looks like it fails around the pinion. Just from the looks of it, it seems as if the Pinion slips open the case. I am thinking the crack first starts from the edge since the there are no ribs for strength and it is much easier to start a crack on an edge then in the middle. Just take riping a sheet of paper for example.

Will it help, who knows but at least it was worth a try.

ShadE · **Posted:** Mon Jan 23, 2006 12:46 pm

Eddo wrote:

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where did you get that ring and what are the specs on it?

Kugellager · **Posted:** Mon Jan 23, 2006 12:54 pm

ShadE wrote:

Eddo wrote:

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where did you get that ring and what are the specs on it?

My thoughts exactly. If it is a weak point than I certainly would want to try what you have to potentially increase the sturdieness...if possible. You are not the first person to suggest that the pinion sleeve end is the weak point where the failures eminate from. That measure taken on each sleeve end can't be that expensive.

John
];')

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

I got it at www.mcmaster.com part number 60665K61

The collar has an inside diameter of 3 1/2" where as the difffernetial housing has a diameter of 3 9/16" at that point. So I just had to sand of a 1/16 of an inch and it slipped right on.

SD-KJ · **Posted:** Mon Jan 23, 2006 2:48 pm

do you have to take off the front drive shaft to put this on, or can you open it up to slide around it?

-Nick

Jeepjeepster · **Posted:** Mon Jan 23, 2006 3:44 pm

What happens if youve got that thing on there and it still blows. Then there is no hope of getting it covered under warranty.

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

It's opens up on both side so you don't need to take off the drive shaft. If it broke while it was on, it only take about a minute to remove so I suppose take it off and before you brough it in.

Jeepjeepster · **Posted:** Mon Jan 23, 2006 4:24 pm

Thats true eddo. But if they saw that 1/16 you sanded off, they would say something like that made it weaker. :lol:

greiswig · **Posted:** Mon Jan 23, 2006 4:45 pm

Jeepjeepster wrote:

Thats true eddo. But if they saw that 1/16 you sanded off, they would say something like that made it weaker. :lol:

I'm guessing he sanded the collar, not the housing.

uvalax236 · **Posted:** Mon Jan 23, 2006 4:46 pm

Jeepjeepster wrote:

Thats true eddo. But if they saw that 1/16 you sanded off, they would say something like that made it weaker. :lol:

I think he ment sand off 1/16" off the collar not the diff.

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

Yes, just a 1/16 of an inch off the collar. I left the diff alone.

Kugellager · **Posted:** Mon Jan 23, 2006 8:53 pm

Eddo wrote:

I got it at www.mcmaster.com part number 60665K61

The collar has an inside diameter of 3 1/2" where as the difffernetial housing has a diameter of 3 9/16" at that point. So I just had to sand of a 1/16 of an inch and it slipped right on.

Ummm...no offense but what exactly would that part be called and roughly where on that page can it be found...there are literally 100's of links and part descriptions on that page.

Thanks,

John
];')

Ed · **Posted:** Mon Jan 23, 2006 9:02 pm

Kugellager wrote:

Eddo wrote:

I got it at www.mcmaster.com part number 60665K61

The collar has an inside diameter of 3 1/2" where as the difffernetial housing has a diameter of 3 9/16" at that point. So I just had to sand of a 1/16 of an inch and it slipped right on.

Ummm...no offense but what exactly would that part be called and roughly where on that page can it be found...there are literally 100's of links and part descriptions on that page.

Thanks,

John
];')

If you put in that part number and hit search then it highlights the appropriate row in yellow, and puts the description just underneath the search box. It's;
Two-Piece Large Bore Clamp-On Collar Steel, 3-1/2" Bore, 4-3/4" Outside Dia, 7/8" Width

Ed · **Posted:** Mon Jan 23, 2006 10:12 pm

Awesome photo indeed, glad it's not my truck though! Two useful words; Mechanical Sympathy

http://www.4x4abc.com/4x4training/trail-repair-course.html

Having said that, I'm very interested in Eddo's "band aid", from the pics of JJsKJ it looks like the crack started right where the little ridge/join/imperfection in the case is, below the input shaft in this picture;

Eddo, are you sure about the measurements for that collar, if it was exactly the right size, wouldn't the two ends of the collar butt up together rather than being a bit apart? Because (it looks like) the collar is a little bit too small do you have to be careful torqueing it down so as not to crush the case and the input shaft bearings?

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

Ed wrote:

Awesome photo indeed, glad it's not my truck though! Two useful words; Mechanical Sympathy

http://www.4x4abc.com/4x4training/trail-repair-course.html

Having said that, I'm very interested in Eddo's "band aid", from the pics of JJsKJ it looks like the crack started right where the little ridge/join/imperfection in the case is, below the input shaft in this picture;

Eddo, are you sure about the measurements for that collar, if it was exactly the right size, wouldn't the two ends of the collar butt up together rather than being a bit apart? Because (it looks like) the collar is a little bit too small do you have to be careful torqueing it down so as not to crush the case and the input shaft bearings?

Hey Ed,

I am sure on those measurements. I know what you are saying that the two ends of the collar will not butt up together. However, that is just the nature of the way those are designed to collars work. There is always a small gap between the two ends so you can decided how much or how little you want to torque it down. You do need to be carefull not to torque it down too much and end up crush something. I just used a 1/4" rachet and got it nice and snugg. You really don't need it that thigh though. Just a good nice snug fit to prevent that area from expanding anymore. Remeber that diff is probably just about strong enough as it is, just needs a little more.

Ed · **Posted:** Tue Jan 24, 2006 10:29 am

Yep, fair enough. I measured it at 3-5/8 so allowing for a crappyness factor of 1/16" in my measurements (it was dark, cold and raining) your 3-9/16 sounds like it would indeed be nice and snug!

Did you really just "sand off" 1/16" of steel? Was that much hassle, and would it be worth looking into getting some of these collars manufactured to the correct size? I guess also adding to the "is it worth it" question is; do we know that this is where all the broken diffs have failed or have some cracked elsewhere?

pixeldzn · **Posted:** Tue Jan 24, 2006 12:30 pm

I found some in a 3 9/16 inner diameter. Problem is they are $80 a piece, vs $20 a piece for the 3 1/2 diamater from the same company.

Thier website is at www.staffordmfg.com and the part number is 8L309. I called direct and they told me a better price is available from local distributors. Local Distributer in Wood Dale, IL quoted me the $80 price. I might just go with his 3 1/2 version and sand it - still cheaper than McMaster Carr.

In any case, it seems a perfect size is available, we just have to find out where to get em cheaper. Anyone have contacts in this industry? JeepinAl?

greiswig · **Posted:** Tue Jan 24, 2006 3:26 pm

Are we pretty sure about this measurement? Getting it right is obviously important. The 3 9/16" measurement is suspiciously close to a 90mm OD, and with so many other things on the Jeep being metric, I wonder...

pixeldzn · **Posted:** Tue Jan 24, 2006 4:15 pm

greiswig wrote:

Are we pretty sure about this measurement? Getting it right is obviously important. The 3 9/16" measurement is suspiciously close to a 90mm OD, and with so many other things on the Jeep being metric, I wonder...

Do you mean a 90 mm INSIDE diameter? The outside diameter is fairly insignificant. We have room to play with that number. Maybe someone with a good set of calipers should get under thier rig and measure. I was thinging it might be a metric thing too. The only thing that makes me think is that it is a Dana unit, which is an american company.

greiswig · **Posted:** Tue Jan 24, 2006 6:26 pm

pixeldzn wrote:

greiswig wrote:

Are we pretty sure about this measurement? Getting it right is obviously important. The 3 9/16" measurement is suspiciously close to a 90mm OD, and with so many other things on the Jeep being metric, I wonder...

Do you mean a 90 mm INSIDE diameter? The outside diameter is fairly insignificant. We have room to play with that number. Maybe someone with a good set of calipers should get under thier rig and measure. I was thinging it might be a metric thing too. The only thing that makes me think is that it is a Dana unit, which is an american company.

I meant the OD of the differential, not of the collar. It might be easier to find a 90mm ID collar than a 3 9/916" ID collar, but either way we need to make sure that the measurement is accurate. A difference of half a millimeter diameter is a couple of millimeters of circumference, and makes a difference in how/whether new stresses are applied to the aluminum housing.

Front Diff Reinforcement Collar

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