Front end clunking after 15 mph

[DOPIESLC]

So I bought a Dana 30 with 4.56 gears in it. The previous owner told me that the cross pin came out and scored the pinion. Upon looking at it I found one chipped tooth and sctratches along the front face. Other than that it was fine. So I installed the axle and drove it. When I reached 15 mph I got a horrible chatter noise that got louder the faster I went. So I changed out all the bearings and races made sure the pattern was still good and drove it again. Chatter is still there and did not change. I have a feeling that this gear set is toast. Does anyone have any other options or do I just bite the bullet and buy a new set of 4.56 gears?

Oh and just fyi for everyone it has brand-new brakes, calipers, rotors, hub bearings, u-joints, axle seals, bearings, ball joints, basically rebuilt minus carrier and gear set.

 

[BLOODBANE]

Just throwing this out there, but bent axle shaft maybe?

 

[DOPIESLC]

Just throwing this out there, but bent axle shaft maybe?

Your on the right track. Something is bent but not the axle shaft. I tore it apart and found the pinion shaft is bent.

 

[SenorNoob]

How the? I'm not even sure I wanna know..

 

[4x4junkie]

Gear problems are not uncommon on a Dana30.

 

[cp2295]

That's nuts!!! Must of slammed down on the yoke or something, I got a Cherokee (I know should've stayed ford) but wanted a cheap dispensable wheeler. Anyways it's got a d30 of course and I've harped on that f***er in 4lo on rocks without it even thinking twice..


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[4x4junkie]

OP said the cross pin had backed out, that's likely what bent his up (thinking about it again, that probably would do in the gears of any axle).

Jeeps tend to be fairly light up front though (lighter than most RBVs). If you're not running real large tires on it, it can hold up pretty decent.

 

[cp2295]

Yeah for sure makes sense about the cross pin. My buddy on 35s harps on his jeep with no issues. He has chromoly shafts and Yukon gears.


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[swifttony]

The issue may be caused by a worn out pinion shaft.