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

[husker25]

Had my 4.56s installed. Guy told me he had to shave down one tooth in the front d30 to get the pinion pin in. He said he had to shave 3 down in the 8.25 in the rear. Gear whine was loud in the rear. Half way home I get a worse noise from the rear only when I'm on the gas.
When I roll to a stop I can hear the gears aren't exactly meshing any longer. I'm taking it back tonight and they're going to break it open again tomorrow. Any ideas?

 

[whitexj98]

Souds like a bad install. I highly doubt that it is from shaving the teeth, unless he had no idea of what he was doing, only a little bit has to come off the rear.

And FYI the front could have been assembled without shaving any teeth, but it doesn’t matter now..

Also did you do a break in?

 

[husker25]

I had a 25 mile drive home-interstate and town driving. I stopped twice for 10 min. to let things cool. I thought three teeth was a bit aggressive, too.

 

[whitexj98]

I had to shave 2 teeh to get mine in, but like I said it wasn't much.

 

[ChiXJeff]

4.56 gears in an 8.25 do require shaving down gear teeth to get the cross pin in, that's pretty well known. 3 does sound a little much, I've heard that if you mate the ring gear to the case properly, you can get it down to 1 tooth.

 

[jeeperjohn]

From what you have said it sounds like the shop does not know what they are doing with jeep axles. If they ground down 3 teeth I would demand they replace the ring and pinion in the rear and they should not have ground down any teeth in the front. If they only ground down 1 tooth in the front it is probably OK but it wasn't necessary.

 

[husker25]

They had the hardest time figuring out how to take out my Aussie Locker. Do you guys think the locker created a harder install situation?

 

[whitexj98]

Sure it adds to the work, But I would think a diff shop would be used to, you know stuff in the diff....

 

[kastein]

If I can do an aussie locker install without grinding gear teeth off, anyone can. And it takes about 5-10min to get an aussie out once you know the trick. As usual, my tricks involve BFHs or brakleen, this one is a brakleen trick. You take the 4 springs out, then spray brakleen in between the pin and the gear half as if you were trying to spray it down the threads of a bolt (stream almost perpendicular to the pin, and tangent to the surface) then spin them in place with a pick, awl, or the point of a utility knife. The brakleen dissolves the thick gear lube which should let the pin slide out easier, remember that the pin is sorta held into the gear half by surface tension and pulling it straight out will try to draw a vacuum behind the pin, so dissolving the gear lube in something thinner makes it easier to let air drag in around the pin so it'll come back out instead of getting sucked back into the gear half when you let go of it. Once you've got them spinning nice and free, sorta spin-pull them out.

It is really not difficult and between that and the grinding and the issues with the gears I think you need to take it back for a redo at minimum, preferably a refund so you can get your gears done by a shop that has some clue what they are doing.

 

[blondejoncherokee]

They had the hardest time figuring out how to take out my Aussie Locker. Do you guys think the locker created a harder install situation?

really? a gear shop that is paid to set gears and install lockers had a hard time with a simple lunchbox? Am I missing something ?

and they are a real gear shop or some friend of a friend sort of thing?

The first time i pulled a lunch box was in the rain in the mud in the junkyard and it still wasnt that bad , without any specialty tools... . since then ive pulled probably 7 from part out rigs and installed just as many of them in my rigs and others rigs in the garage, way easier. Ive never setup gears, but swapping a lunchbox is one of the easiest things one can do.

Also, why did they not install the lunchbox then the ring gear onto the carrier ?

The only time ive shaved a ring gear is when I didnt want to pull the ring gear off the carrier and I was swapping it onto a 3.55 ring gear/stock carrier situation. with the ring gear off, it should be easy right?

of course, ive never done a lunchbox in a 8.25, only a bunch of 30s and a couple 35s, and a 44...

something seems odd.

 

[kastein]

You have to grind a tooth or two to put an aussie in a stock 3.55 geared axle without pulling the ring gear off, but come on, it's a 3.55 geared d30. It is literally almost worthless. Grinding a tooth or two isn't going to matter at all and even if it does there are two dozen at the boneyard.

 

[VAhasnoWAVES]

They had the hardest time figuring out how to take out my Aussie Locker. Do you guys think the locker created a harder install situation?

installing the aussie shouldnt be any harder than installing spider gears...

:dunno:

 

[whitexj98]

Some confusion hear...

The Dana 30 can have the carrier assembled before putting the ring gear on so you don’t have to grind any teeth (but can if you so desire)…

But...

On a lunch box install on a C clip axle (C8.25), the only way to assemble the locker or spider gears is with the carrier installed, no big deal with stock gears but when you have thicker ring gears like on a 4:56 set the cross pin will not clear the ring gear requiring shaving a couple teeth.

 

[jeeperjohn]

On a lunch box install on a C clip axle (C8.25), the only way to assemble the locker or spider gears is with the carrier installed, no big deal with stock gears but when you have thicker ring gears like on a 4:56 set the cross pin will not clear the ring gear requiring shaving a couple teeth.

This is true but I have never seen it be necessary to grind 3 teeth. It sounds like the shop is simply way inexperienced.

 

[Digger87xj]

just installed 4.88s and an aussie in a 8.25 last friday...

one tooth had to be ground off on the heel to fit the pin, and getting the c-clips in can be a chore.

Haven't had to take one out yet but it can't be fun fighting the pin springs.

 

[kastein]

Use the method I posted and it all comes apart pretty easily. Getting the springs out is easiest with a tiny flat blade screwdriver or a fine pointed hook ended awl/pick.

 

[Outlander560]

when you guys talk about grinding teeth down your just talking about grinding it down at the heel a little I hope your not talking about grinding an entire tooth from heel to toe down

 

[Johnnie Walker]

when you guys talk about grinding teeth down your just talking about grinding it down at the heel a little I hope your not talking about grinding an entire tooth from heel to toe down

They mean juat a small amount from the inside for clearance for the pin.

 

[jeeperjohn]

They mean juat a small amount from the inside for clearance for the pin.

^ this

 

[gpnmoab1]

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.