Problem after installing 4.56s in 8.25--had to shave off/down three teeth

[whitexj98]

This sounds really suspect. I have 4.56 installed into an 8.25 and the D30 and no gears were shaved. The LB locker in the rear was installed first then the ring gear so no gears needed shaved. I can still replace the rear axles if needed and have done so. I have a Eaton E-locker up front which is self contained so again no shaved gears.

Unless you have something I'm not aware of theres no way to install the locker out of the axle before installing the ring gear on a c clip 8.25.

Also your'e saying you can pull the cross pin straight out and it clears the gearset no problem with no clearencing done anywhere?

Are you sure you have an 8.25...:looney:

 

[kastein]

Yeah, uh, I'm with whitexj98 on this one. Unless someone makes a c clip eliminator kit for the 8.25...

 

[Jimmyrigd]

I normally grind a flat spot into the cross pin to clear the ring gear. you don't have to take off very much. Just make sure you grind it 90 degrees from where the axle touchs it. By the way I have done this on many rearend a 8.8s and 8.25 and never had a cross shaft failure

 

[VAhasnoWAVES]

I normally grind a flat spot into the cross pin to clear the ring gear. you don't have to take off very much. Just make sure you grind it 90 degrees from where the axle touchs it. By the way I have done this on many rearend a 8.8s and 8.25 and never had a cross shaft failure

if doing this, id probably spring for a hardened cross shaft, like the ones that come with the spartans.

 

[Jimmyrigd]

I have never seen a cross shaft failure be the root cause of a rearend failure. I have ground probably 2 dozen all in offload applications and have never had a problem. Something about grinding the ring gear never felt right.

 

[XJ jay]

I dont recall grinding down my 4.56s to get the cross shaft in, but it was a year ago, anyway, looking forward to seeing what the outcome is.

 

[sunburned]

I normally grind a flat spot into the cross pin to clear the ring gear. you don't have to take off very much. Just make sure you grind it 90 degrees from where the axle touchs it. By the way I have done this on many rearend a 8.8s and 8.25 and never had a cross shaft failure

My friend who installed the gears on my Jeep tried this the first time. he ground down a flat in the hardened cross pin from the no-slip locker we were putting in. The locker didn't work correctly afterwards and he ordered another pin and ground down the teeth instead. Worked fine with the normal pin.

Strangely enough, probably 4 years after I put those gears in, I started getting noises from the rear end on a wheel trip. I ended up breaking 4 teeth off the 8.25 (4.56) ring gear, two teeth in two different spots. Still drove fine, just made weird noises. The ground down teeth weren't affected.

 

[gpnmoab1]

Unless you have something I'm not aware of theres no way to install the locker out of the axle before installing the ring gear on a c clip 8.25.

Also your'e saying you can pull the cross pin straight out and it clears the gearset no problem with no clearencing done anywhere?

Are you sure you have an 8.25...:looney:

yes you can install a lunch box locker in or out of the axle housing. The locker has nothing to do with the ring gear. It goes inside the carrier. When you use 4:56 gears, yes you cannot pull the cross shaft after the ring gear is installed. that is why you install the locker first, then install the ring gear. after that you install the axles. the cross shaft is custom and provided with the locker. You basically loosen the retaining pin and turn the cross shaft. Its center is flat and allows enough clearance to remove part of the locker. Once that is done you push the axles shafts in and remove the clips. The axles slide right out. You reverse these steps to re-install the shafts. It's well thought out by Powertrax.... I do have a 8.25. Hope this helps, sorry for the late response

 

[RSQJEEP]

I have 4.56 in my dana 30 on my TJ and it never had any teeth shaved down. What brand gears did you go with? Sounds sketchy....

 

[VAhasnoWAVES]

the cross shaft is custom and provided with the locker.

pics of said cross shaft?

 

[Vanimal]

I have never seen a cross shaft failure be the root cause of a rearend failure. I have ground probably 2 dozen all in offload applications and have never had a problem. Something about grinding the ring gear never felt right.

i've seen several break over the past year. Hell, i broke one in my van's 10 bolt a couple months ago. I used to break 1-2 a year in the 4t60e in my buick regal. similar in size to stock xj axles too. that was most definitely the root cause, being the only thing that broke in most occasions.
I would say grinding the pin is a bad idea. generally they're case hardened, and you're likely grinding through that and creating a huge stress riser. grinding the ring gear where there is no contact patch isn't hurting anything.

 

[whitexj98]

yes you can install a lunch box locker in or out of the axle housing. The locker has nothing to do with the ring gear. It goes inside the carrier. When you use 4:56 gears, yes you cannot pull the cross shaft after the ring gear is installed. that is why you install the locker first, then install the ring gear. after that you install the axles. the cross shaft is custom and provided with the locker. You basically loosen the retaining pin and turn the cross shaft. Its center is flat and allows enough clearance to remove part of the locker. Once that is done you push the axles shafts in and remove the clips. The axles slide right out. You reverse these steps to re-install the shafts. It's well thought out by Powertrax.... I do have a 8.25. Hope this helps, sorry for the late response

My new powertrax no slip did not come with a cross shaft, nor did I see an option for one making my only options to grind a few teeth or grind the cross shaft. I ground the teeth.

I have 4.56 in my dana 30 on my TJ and it never had any teeth shaved down. What brand gears did you go with? Sounds sketchy....

You don't have to on a dana 30 because you can install the locker in the carrier before putting on the ring gear because it's a non c clip axle.

 

[Digger87xj]

My new powertrax no slip did not come with a cross shaft, nor did I see an option for one making my only options to grind a few teeth or grind the cross shaft. I ground the teeth.
.

It should have come with one. You got shorted.

 

[sunburned]

My new powertrax no slip did not come with a cross shaft, nor did I see an option for one making my only options to grind a few teeth or grind the cross shaft. I ground the teeth.

Agree with above. The no-slip comes with a hardened cross shaft, I'd give Richmond Gear a call.

I'll say it again though. My no-slip did not work correctly when my mechanic ground down the cross shaft enough to get it in with the 4.56 gears. It wasn't locking when it was supposed to and generally acting strange. Bought a new pin and shaved the teeth instead, worked perfectly. The shaved teeth didn't affect a thing.

 

[whitexj98]

Agree with above. The no-slip comes with a hardened cross shaft, I'd give Richmond Gear a call.

I'll say it again though. My no-slip did not work correctly when my mechanic ground down the cross shaft enough to get it in with the 4.56 gears. It wasn't locking when it was supposed to and generally acting strange. Bought a new pin and shaved the teeth instead, worked perfectly. The shaved teeth didn't affect a thing.

I got my no slip 7 years ago...

Does your coss shat have flats on it like gnpmoab1 said?

 

[sunburned]

I got my no slip 7 years ago...

Does your coss shat have flats on it like gnpmoab1 said?

I got mine at least 5 years ago. I don't think mine has flats on it. It needs to be round to work correctly.