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High Horsepower Front Axle Swap Ideas

Discussion in 'Early CJ5 and CJ6 Tech' started by 66_Cj5_Explorer, Nov 3, 2019.

  1. Nov 4, 2019
    Glenn

    Glenn Kinda grumpy old man Staff Member Sponsor

    Apopka, Fl
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    That is an interesting point to make and I kinda wondered the same thing. You'd think the gravel would be loose enough to not provide that much traction.
     
  2. Nov 4, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    I was wondering the same thing. The pinion is a weird thing to break without there being other underlying issues.
     
  3. Nov 4, 2019
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member Sponsor

    Denver, CO
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    I don't know if its the right solution in terms of usage and cost, but seems like a D44 built well and used with a little caution (manage the skinny pedal) would be workable - kind of like what Duffer is doing.
     
  4. Nov 4, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

    Huntsville, AL
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    I
    I didn't have the rear drive shaft in it when this happened I don't know if that would make a significant difference. It had just been flat towed 2000 miles by me after checking fluids and basics. I had it running well for 12 hours before this happened with about 4-6 lengths of my short gravel driveway. I'm pretty sure the gear ratios were the same front and back as it was used frequently in the 1980s by my Dad with the 350 sbc otherwise same setup. I was accelerating to go forward again when all I heard was a 'ping' sound then the jeep wouldn't move. Rear drive shaft is back in and it moves fine with that; at least so far.
     
  5. Nov 4, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

    Huntsville, AL
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    I haven't taken the differential cover off yet to fully inspect the carnage but there is what I think would be part of the pinion or carrier support poking through the cast iron housing upper portion. The ping i heard was a piece of the housing being punched out. It was lying on the ground near the spot where cylindrical metal peice is sticking out of the housing just about 3/4 of an inch.
     
  6. Nov 4, 2019
    colojeepguy

    colojeepguy Colorado Springs Sponsor 2019 Sponsor

    At the foot of...
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    Yeah....you were routing ALL the power through that front axle. Not too surprised that it broke.
     
  7. Nov 4, 2019
    47v6

    47v6 junk wrecker! Sponsor

    Washington DC.
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    We really need several pics of this carnage, you know, for science or something..
     
    Jrobz23, baldjosh, Glenn and 2 others like this.
  8. Nov 4, 2019
    Glenn

    Glenn Kinda grumpy old man Staff Member Sponsor

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    That's certainly a reasonable request. :)
     
  9. Nov 6, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

    Huntsville, AL
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  10. Nov 6, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

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    I'm not sure when I take the differential cover off but when I do I'll post that also.
     
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  11. Nov 7, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

    Huntsville, AL
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  12. Nov 7, 2019
    Glenn

    Glenn Kinda grumpy old man Staff Member Sponsor

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    It's amazing what can happen with just a little bit more power. :D
     
  13. Nov 8, 2019
    47v6

    47v6 junk wrecker! Sponsor

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    The cross shaft and cross shaft pin.... The case looks wallowed out with some corrosion in the area where the cross shaft is inserted. To me that indicates a long term issue. Is there a cross shaft pin? Was it ever installed? Do you think this could have been improper assembly? There looks to be no other carnage as in ring gear or pinion failure..

    I'm not convinced this is HP related.
     
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  14. Nov 8, 2019
    nickmil

    nickmil In mothballs. Sponsor

    Happy Valley, OR
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    Probably wore through the roll pin that holds the pinion shaft in place and let the shaft walk out. I've seen it before many times. Normally from lots of hard use. We used to machine Dana 44 cases and install a hardened threaded retaining pin from a Ford to eliminate this when we installed locking diffs that replaced the side gears and pinion gears (Aussie Locker, etc.).
     
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  15. Nov 8, 2019
    aallison

    aallison 74 cj6, 76 cj5. Has anyone seen my screwdriver?

    Green Cove...
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    agree, not solely related to HP. However it would have happened sooner or later. As I understand it sat for years without being driven and then just the front axle was under power. I think if you rebuild it and drive with some caution it may last for many years. Or swap in something that can handle the HP. You can get up to a shortened D60 front that will look stock.
     
  16. Nov 8, 2019
    OzFin

    OzFin Vintage Jeep Guy

    Michigan
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    Can we see a better view of this:
    [​IMG]

    Is that the cross shaft sticking through the axle?
     
  17. Nov 8, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

    Huntsville, AL
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    The first picture of my previous post has the inside view of that shaft that is sticking through the housing.
     
  18. Nov 8, 2019
    66_Cj5_Explorer

    66_Cj5_Explorer New Member

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    I'm leaning towards a dana 60 front replacement even with the reduced ground clearance. If I did at some point go to 37s what width range would work best? I've seen lots of info online for later models which have a wider body and frame stock.
     
  19. Nov 8, 2019
    jeepstar

    jeepstar Sponsor Sponsor

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    Rockwell axle build time
     
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  20. Nov 8, 2019
    OzFin

    OzFin Vintage Jeep Guy

    Michigan
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    Okay, I went back a looked at the other picture again., that's a spectacular failure. :(
    I can't help with the Dana 60 recommendation, though others may chime in with advice. Good luck in whatever you choose to do.
     

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