Operation: Bullet Proof Rear Axle

[Albuquerque Jim]

If you have seen any of my previous threads you know that I have destroyed 2 rear diffs in the last 6 months. The 3.4 with a crawler put down an unbelievable amount of torque :confused:

Prior to that I have actually been through 3 rear diff housings.

Original, non-elocked
Swapped in an e-locked
Swapped in a non-elocked with a retro fit conversion (After I determined the swapped e-locked axle housing was bent)


The final axle housing is doing well, when I retrofit the e-locker I built a nice weld on rear diff guard. It's made from .120 wall 2" tubing and 3/8" plate. (thanks Josh). This diff guard is Step 1 for Operation: Bullet Proof Rear Axle

http://pics.montypics.com/albuquerque_jim/2006-02-20/1140504419_diff_armor_005.jpg

Along with the diff guard I added an e-locker skid plate, made with 1/4" plate Step 2

http://pics.montypics.com/albuquerque_jim/2006-02-20/1140505412_diff_armor_034.jpg

Now back to me breaking things...I don't want to break any more diffs or any other rear axle parts for that matter.

Step 3 arrived in the mail today, Poly Performance Chromo Shafts

http://pics.montypics.com/albuquerque_jim/2007-05-08/1178670908_p5080094.jpg

Step 4 is being built by Zuk at www.gearinstall.com an e-locked 3rd member set up with 4.30 gears Cryo treated by Bobby Long with a solid spacer instead of a crush sleeve (I will post pics when complete)

This should take care of my rear diff problems :thumbup:

[Bighead]

This should take care of my rear diff problems :thumbup:

I hope so...I don't know what you would do next.

[neliconcept]

looks stout, just curious about your crawler setup, do you have a twinstick or a second shifter somewhere behind near the cupholders?

anyways hope that fixes the rear diff blowouts

[waskillywabbit]

If that DOESN'T fix it you are SOL.

:guitar:

[sschaefer3]

Dana 60 is next or the Heavy Duty Viper/Corvette Dana 44 HD.

There are a few next steps with bigger ring and pinion.

I have the Dana 44 HD already.

[jimbo74]

If that DOESN'T fix it you are SOL.



Dana 60

i say d60 next

[Albuquerque Jim]

looks stout, just curious about your crawler setup, do you have a twinstick or a second shifter somewhere behind near the cupholders?

anyways hope that fixes the rear diff blowouts


I have a short throw in the front cup holder. It is a copy of Schaefer's original design. It's pretty slick IMO. If you didn't know, you would think it was stock. I'll take a pic in the daylight.

I am confident that this will be the end of my rear axle issues. No more running high mileage diffs to try and save a buck. This rear axle should with stand 40's, and it will only see 35's.

PS, I heard from Zuk this evening. I should have my diff back early next week.

[Lee]

wow looks incredible :)

post more pics, and please post pics of your dual case setup :)

[Cheese]

If it breaks, you put a Tundra diff Diamond in.

Obviously I have been out of the loop, but I was unaware you killed that many diffs.

The spacer and cryo should cover all the bases.

At the risk of starting a way, the problem is not size. I would not be stoked to hang a 60 diff everywhere with your 35's.

Good work.

[Albuquerque Jim]

If it breaks, you put a Tundra diff Diamond in.

Obviously I have been out of the loop, but I was unaware you killed that many diffs.

The spacer and cryo should cover all the bases.

At the risk of starting a way, the problem is not size. I would not be stoked to hang a 60 diff everywhere with your 35's.

Good work.


Good point, the 60 would be a rock anchor with 35's...

You know the new Tundra has a 10.5" ring and it comes with 4.30's :D

[BruceTS]

If I ever grenade another rear R&P set, I'm going back to 4.10's........

At least that's what's going into my new project vehicle........

[SteveO]

I wouldn't go D60. Rather, a Ford 9" has plenty of beef, and you can get it with a high pinion setup and disc brakes.

[sschaefer3]

I picked up that Dana 60 for you that you paid for. I'll bring it up to you next week.

[Albuquerque Jim]

Thanks Man.

[SteveO]

I'm sure that D60 will look great with 34.5" tires on it.

[sschaefer3]

I am going to have to get a small army of dudes to move the thing. It sags my trailer out to the max !!!

[Albuquerque Jim]

I'm sure that D60 will look great with 34.5" tires on it.


It will match nicely with the D60 I have sitting here for the front.

Wait till you see the 39.5" IROKs. They fit nice with the fenders trimmed to the area where the flares used to go.

[mastacox]

I'm sure that D60 will look great with 34.5" tires on it.


It will match nicely with the D60 I have sitting here for the front.

Wait till you see the 39.5" IROKs. They fit nice with the fenders trimmed to the area where the flares used to go.


So, are you really SAS'ing Jim?

[SteveO]

If you really are running 39.5" Iroks, then a D60 is in order. But, after putting so much money into the rear 3rd, why would you put more into D60 axles?

[sschaefer3]

Hey- the plug on my plasma cutter is NOT a 220V dryer plug. You need to go to ACE and get one for a welder. 220V welder plug.

[Cheese]

So I will see you in the morning to help unload?

Looking forward to the build thread.

[mastacox]

Haven't looked at this thread in a bit, and I realized something:



It will match nicely with the D60 I have sitting here for the front.

When cutting metal happens, can I buy your manual hub "conversion" you have for your IFS? Could be it's already been sold but I figured I'd ask anyway, since those parts are a bit difficult to come by.

[neliconcept]

damnit i was gonna ask for his front and rear thirds,

trail rig only? or will you drive on a set of street tires and have the 40 iroks as the offroad set