Power lock: junk or not

Opened up this dana 27 Power Lock tonight. I found 2 obvious issues.

1) The side gear rings ( are these also called clutch rings?) shows half moon shaped wear marks on the tapered surfaces that face the side gears. Does this mean they are junk? All other surfaces and splines appear to be in good condition. Replacements are available should replacement be necessary.

2) One side gear is spent with large chips/chunks missing from several teeth. Similar but smaller damage is evident on two of the spider gears. One reputable source I have contacted says these parts are not available through them, new or used.

So, am I better off to try to repair this unit if I can find the side/spider gears somewhere, reasonably priced or am I better off to junk it and look for another good used unit?

 

if the clutch discs are the same as a dana 30 are the rest of the internals the same?

 

1) Normal wear.

Going to be hard to find the other components.
25 and 27 internals are the same if I recall.
25, 27, and 30 clutch packs are the same.
30 spiders are 27 spline?; 25 and 27 are 10 spline.

Both units can be like trying to find hen's teeth.
I wouldn't toss it, cases and cross shafts are hard to find as well.
Cruise the early Scout forums as 27 axles are junk to them.
IH supplied a lot more axles with factory power loks than Jeep..well, maybe.

 

wear pattern look like this on the side gears?

 

Yea, that's how it looks. I didn't clean it up yet, though. Seems like a funny wear pattern. Is that the side gears moving around in there? I thought it might be damage from the broken side gear or from worn cross shafts or something. So, I can reuse the part?

Not really sure what I should be looking for in terms of the case halves.

 

Wheelie,
I have a 27 PL on my work bench. I am happy to open it up and take pictures to show you what mine looks like.

But will not be back to my work bench until Friday night.

toolman_ar

 

Yes, you can re-use it.
The challenge as mentioned is finding good side gears and spider gears.
They almost always have to come from a donor unit.

 

Don't go out of your way, toolman. I'll put up a few shots of the case, later, and see what folks think. The only think I could see being an issue with IT is where the cross shafts sit. So far, that seems fine as there was no clearance between the shafts and the case before disassembly.

 

Yes the half moon wear pattern found on the side gear cups is acceptable if not too deep.
In fact upon re-assembly you can rotate the side gears inside the cups to utilize the unworn area of the cup.

Model 25 and 27 Powr Loks are 100% interchangable excepting the case halves and the case bearings.
Also some cases may be RHT while others use LHT bolts.

 

What Oldtime said. The side gears, pinion gears, and pinion shafts can be hard to find as no longer made (haven't been for quite a while). Check the pinion shafts for galling/wear and make sure they are straight. Common for these to bend. Make sure the pinion gears are not galled where they ride on the shaft also. Early Scouts are a good source for 27/25 Powr Lok parts. They didn't use the 25, just the 27.

 

Herm now has complete sets of reproduction replacement parts available but they are pretty spendy. No one has had kits for these for a long time. If you want to run these it is going to cost a premium to rebuild worn units.

 

However you can find clutch disk kits to fit.
Same clutch disks fits D25, D27, D30.

 

Didn't know he actually had them up and going. I know he was talking about it for quite a while. Good info.

 

I knew he had the shafts, didn't know about gears.
Don't know if I would trust them anyway....

 

I'll put some pics up of the side gears then. They look kind of shot to me but maybe not as bad as I think. I can feel the wear but it's not like REAL deep.

I doubt I can afford "spendy" new gears. I'll spend a little time looking for good used (see WTB in classifieds). In the meantime, I'll inspect the shafts, case, etc. more closely.

These parts are the same regardless of whether they are in a series 3 or series 4 case, correct.

I know where there is a 19 spline Dana 44 power lock. Nothing from that would interchange, I suppose? I could use them in trade though.

 

44 components won't interchange with 25/27.
Parts are the same between 3 and 4 series for the 27.
Here's a shot of 44 side gear and side gear cups showing the wear pattern yours may exhibit.
The last photo is what new ones look like, although those are 44.
As long as the hardened areas aren't worn thru or peeled back, they should be okay.

 

"Houston. We have a problem."

So, uhhh, those cross shafts.........they are supposed to each be 1 piece, not 2 pieces. Yea. I thought that seemed sort of wrong when I opened up the case. They are broken in half, both of them.

Aa-uuundd......I cleaned up the side gear rings and they show galling in the worn areas and look much worse than the used ones you pictured.

I think I struck out on this unit. I haven't gotten prices on parts from the source that says they have them but, I think I might have more in parts to rebuild this unit than I would have in a good used unit that just needs new clutch packs.

At this point I need side gear rings, side and spider gears, cross shafts and clutch packs.

 

Sounds like its all trash except for case.
How do the the case halves and case bolts look ?

 

what 25/27 good stuff looks like....except for the clutches