Dana 18 Rebuild: How Many Shims?

I know how to find the proper number of shims with a dial indicator but how many should it take? I'm using a new shim pack from Kaiser Willy's and even with all 8 I have absolutely zero endplay, gears don't even want to turn. I believe everything is seated all the way on the shaft, I tried installing the yokes and speedo gear and torquing them, tapping the shaft on either end, tapping the front and rear bearing housings, all that stuff, nothing, gears still won't spin. Should I order more shims or is something amiss?

 

I'd say something not right....maybe one of the bearings not fully seated?

 

I'd be making sure all the bearing races are fully seated, as well as bearings bottomed out on the shafts. I can't see how a full stack of shims still isn't enough. Are all your shims "foil" thick, or are there some thicker ones in the pack too?
-Donny

 

How many were removed during disassembly ?
Proves nothing, just for giggles.

 

I know the bearing cones are good, I seated the front bearing cup by slowly tightening the front output housing and it's nice and flush so it should be good too, I've tried tapping the shaft so I have to imagine that seated everything as well. I even put both the yokes on and everything. I'm putting the guts from my small bore 1 1/4 intermediate Dana 18 into a big bore Dana 20 case if that matters.

 

The shims all appear to be the same thickness. Did I just get a crappy shim pack?

 

My shim pack had a lot more than 8 shims in varying thicknesses. I may still have a few floating around.

 

I loosened the rear output housing until I had the proper endplay (about .003). It appears as though I'd only need one or two more shims of whatever thickness these are (my calipers are broken). Everything else looks good so I'm going to get some more shims and try it out. Jzeber if you have some shims laying around I'd pay postage for you to mail them to me. EDIT: actually with the current craziness I won't make you do that haha. Bought a NOS set from the internet.

 

Mine all appeared to be the same, hopefully the new shim pack remedies the problem.

 

I'll take a look. I have shipping packages here if you still want them.

 

I mean I won't say no as long as it isn't a big inconvenience for you. If you find them send me a message and we'll work out how I can send you some money. Thanks!

 

If you loosened the output to get what you need. Then it needs less shims. I always use the old shims. The new shim packs don't have very many thinner shims. .003, .005, and .008's are good to have.

 

It has too little endplay when fully tightened (gears binding), my apologies if I worded that improperly. I ordered a NOS shim pack so hopefully that will have some more versatility and allow me to achieve proper endplay.

 

I ran into the same thing when I rebuilt mine. Shim pack was all one thickness. I thought I was doing something wrong, but I checked it a million times, and it still took like a pack and a half of the new shim packs they sell these days. Took for ever to spray, flip, spray, and stack em all! Good luck!

 

Thanks! I wish I knew this going into it, I was freaking out.

 

Shimming my Transfer case was an all day job for me, I could never get the numbers I wanted to work out, after I got what I thought was good, It was tight after putting sealer on it, so I took it apart and removed one shim, put it back together, torqued it all up again, it came out in the numbers suggested, still good after it was all back together. No problems yet, still good, as far as I know. I too was "Freaking Out" Could never sure it was right. Good Luck

 

I looked around a little for the shims yesterday with no luck. Since moving over 18 months back I still can't find things. I'll take another look today.

 

No worries! I'll just get some new ones.