4wd Is Broken

also...why on earth would my axle splines not spin without lockouts? that little tiny spring makes everything engage?
when I got the jeep, there weren't lockouts, just caps on the front axle.

 

when the 4wd is engaged, the driveshaft spins, as does the yoke attached to the diff
re read nicks post #13

 

I only ever broke axleshafts in my dana 25/27. Both were V8 powered. Never broke em going forward. Anytime it happened I was pulling backwards on something. My money is on either spiders or a broken shaft. Time to pull the cover and look.

 

The hubs are disconnected, the four wheel drive is engaged and the drive shaft spins but the axle splines do not.

 

Looks like the horizontal pin shattered

 

Well, there's your problem!

Sorry to see that, but it's always interesting to look at gear carnage.

 

now that said it all . might be able to get a used shaft . in classified section

 

Each of the 2 remaining spider gears have a missing tooth each.
1. either new spider gears are on order, or..
2. I talked to the father in law, he has a complete dana 30 from a 79. Said i may be able to swap out the carriers? What do you guys think?

Vendor recomendations? Any difference between a 90 dollar set vs. a hundred 10 dollar set, other than the 20 bucks? I do not want to have to go through this again since it is all apart. Knew it wasnt improperly locking hubs

 

Dana 30 parts will not work.
When I installed my dana 30 (2005) I had to re-gear it, I got a decent set of used gears off eBay for $30. A used center chunk would be fine so long as its not a rusty mess in your case. I would just hunt a set of spider gears that are in good shape.

 

I'd probably go the other route, and put that whole D-30 under it, re-gear it to match the rear if needed, go saginaw power swap (if you haven't) and be done.

there's a guy on the local CL that's got a lot of them, but your mileage may vary (JEEP Model 25 & 27 Spider Gears).

 

Before making a decision I'd suggest cleaning all that mess out thoroughly, inspect the remaining parts including the ring and pinion and the case where the pinion shaft goes through for damage and wear, then start looking at options.

If you're lucky all you need is a new (or good used) pinion shaft and a couple pinion (spider) gears and maybe side gears. Don't forget to look at the thrust washers for both the side gears and pinion gears. If these wear out the gears can spread apart and be weaker because of not enough tooth contact between them.

 

Nick is right, mark your caps when you take it apart, check everything, good time to replace axle seals, by the color of the pudding there is water there.
You can find a whole pumpkin used, pretty cheap, if needed or give up on this and put in a Dana 30, but that could cost lot more money, regearing, spring purches, u bolts, front driveline, change master, etc?
I think Daryl has a complete one still for sale on here, or he would have the parts to help you?

Rick

 

Hate to see carnage like that especially when it is not intentional.

 

I'll look everything over. It doesn't look like there's too much damage because I wasn't really doing anything serious off-road. I think for $100 or so I'll just buy new spider gears for this axle. I like to keep it stock.

 

I may have a set if you have trouble finding what you need.

On a side note:

I think the Dana 27 gets a bad rap. A D30 may be in my future because I picked on up for free.... but I have been running mine for 20+ years with 33 inch tires on some decent "hardcore" trails (Rubicon, Mirror Lake, Dusy Ersham.... etc.) I have run a powerlock and now a Lockrite with no damage so far. And it has held up fine.

 

I have no trouble. but if yours are cheaper....im all about that. flat ship it to Sheboygan would be...?

also, thinking about putting a locker in. would this make sense?