Voyage of The Black Gypsy

In A Clutch

The shop got the clutch installed and I picked the Jeep up yesterday and took her for a test drive. Shifting is smoother and much easier. I really like the Centerforce.

The old clutch disc was worn almost to the rivets and the throwout bearing was destroyed. I'm surprised and gratified it got me home.

Test drive went well except for the tire going flat after I parked at the airport. Took forever to air up with the little portable air compressor. Took it to @Discount Tire . It couldn't be fixed, but as I had their road hazard protection a new replacement KM3 was installed for just $55. Discount Tire has the best customer service. Everyone is friendly and cheerful and as a bonus, they offer a military discount that stacks with other discounts. I'll be using them again when we get new tires for the wife's Grand Cherokee.
 
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I only use DT for my vehicles. I have had the same experience as you in terms of service and care every time I’ve gone in. Added bonus is they are nation wide, so I don’t have to worry about being out of state and having tire trouble.
 
Rear pinion nut backed off and the axle started vibrating when decelerating. Opened up the did cover and found this
IMG_9567.jpeg
The pinion teeth chewed into the diff housing, leaving metal chunks everywhere. Pulled it apart and cleaned everything
IMG_9582.jpeg
IMG_9584.jpeg

Now I’m waiting for the rebuild kit and a few other parts to come to reinstall everything.

Here’s the dilemma. Do I take this opportunity to install 4.88s? Or do the responsible thing and wait until I land a new job?

Decisions, decisions…
 
GP NOIR said:
Rear pinion nut backed off and the axle started vibrating when decelerating. Opened up the did cover and found this
View attachment 417714
The pinion teeth chewed into the diff housing, leaving metal chunks everywhere. Pulled it apart and cleaned everything
View attachment 417715
View attachment 417716

Now I’m waiting for the rebuild kit and a few other parts to come to reinstall everything.

Here’s the dilemma. Do I take this opportunity to install 4.88s? Or do the responsible thing and wait until I land a new job?

Decisions, decisions…
Click to expand...
Is the install something you can handle doing by yourself?
 
GP NOIR said:
Rear pinion nut backed off and the axle started vibrating when decelerating. Opened up the did cover and found this
View attachment 417714
The pinion teeth chewed into the diff housing, leaving metal chunks everywhere. Pulled it apart and cleaned everything
View attachment 417715
View attachment 417716

Now I’m waiting for the rebuild kit and a few other parts to come to reinstall everything.

Here’s the dilemma. Do I take this opportunity to install 4.88s? Or do the responsible thing and wait until I land a new job?

Decisions, decisions…
Click to expand...
on the one hand ... on the other hand....
1733583926887.png
 
GP NOIR said:
Rear pinion nut backed off and the axle started vibrating when decelerating. Opened up the did cover and found this
View attachment 417714
The pinion teeth chewed into the diff housing, leaving metal chunks everywhere. Pulled it apart and cleaned everything
View attachment 417715
View attachment 417716

Now I’m waiting for the rebuild kit and a few other parts to come to reinstall everything.

Here’s the dilemma. Do I take this opportunity to install 4.88s? Or do the responsible thing and wait until I land a new job?

Decisions, decisions…
Click to expand...

Carnage! Glad you were able to stop safely and perform a tear-down and assessment.
 
GP NOIR said:
Rear pinion nut backed off and the axle started vibrating when decelerating. Opened up the did cover and found this
View attachment 417714
The pinion teeth chewed into the diff housing, leaving metal chunks everywhere. Pulled it apart and cleaned everything
View attachment 417715
View attachment 417716

Now I’m waiting for the rebuild kit and a few other parts to come to reinstall everything.

Here’s the dilemma. Do I take this opportunity to install 4.88s? Or do the responsible thing and wait until I land a new job?

Decisions, decisions…
Click to expand...
Time is money. 4.88s!
 
Experience is the harshest of teachers. She gives you the test first and the lessons after.

This is my first regear and there were many challenges to overcomes. Working in an open shed in the wet cold. Learning how to perform each step. Doing it one more time to get things within spec when I was tired, cold, hungry and wanted to be done with it. Being patient when things didn’t go as planned or when a mistake cost work, time and money.

IMG_9636.jpeg
All the hard work is done. Gears are in, backlash is set and gear pattern looks good. Axle shafts and brakes are reinstalled. A couple of electrical connectors need repairs and the diffs serviced with gear oil.
IMG_9697.jpeg

IMG_9655.jpeg
Along the way, I discovered a couple of new tools and ways to do things.
IMG_9614.jpeg

IMG_9638.jpeg

IMG_9652.jpeg

Setting the backlash and preload wasn’t as bad as I thought they’d be. It got easier and easier each time I rolled the carrier in and out. Documenting each change and the results is a must.

If I had to do it over again, I would have simply cleaned out all the metal chips, stuffed the diff back in its housing and waited till spring to regear. I would have made it to the New Year’s Run and a few other trails. That said, I’m glad for the experience and lessons learned.

Can’t wait to attend to the remaining details and finish the job. I’m looking forward to finding out how Gypsy performs with 4.88s and 35s.
 
GP NOIR said:
Experience is the harshest of teachers. She gives you the test first and the lessons after.

This is my first regear and there were many challenges to overcomes. Working in an open shed in the wet cold. Learning how to perform each step. Doing it one more time to get things within spec when I was tired, cold, hungry and wanted to be done with it. Being patient when things didn’t go as planned or when a mistake cost work, time and money.

View attachment 419012
All the hard work is done. Gears are in, backlash is set and gear pattern looks good. Axle shafts and brakes are reinstalled. A couple of electrical connectors need repairs and the diffs serviced with gear oil.
View attachment 419013

View attachment 419014
Along the way, I discovered a couple of new tools and ways to do things.
View attachment 419015

View attachment 419016

View attachment 419017

Setting the backlash and preload wasn’t as bad as I thought they’d be. It got easier and easier each time I rolled the carrier in and out. Documenting each change and the results is a must.

If I had to do it over again, I would have simply cleaned out all the metal chips, stuffed the diff back in its housing and waited till spring to regear. I would have made it to the New Year’s Run and a few other trails. That said, I’m glad for the experience and lessons learned.

Can’t wait to attend to the remaining details and finish the job. I’m looking forward to finding out how Gypsy performs with 4.88s and 35s.
Click to expand...
Gears are a pain in the ass but rewarding to do it and appreciate what's involved.
 
GP NOIR said:
Experience is the harshest of teachers. She gives you the test first and the lessons after.

This is my first regear and there were many challenges to overcomes. Working in an open shed in the wet cold. Learning how to perform each step. Doing it one more time to get things within spec when I was tired, cold, hungry and wanted to be done with it. Being patient when things didn’t go as planned or when a mistake cost work, time and money.

View attachment 419012
All the hard work is done. Gears are in, backlash is set and gear pattern looks good. Axle shafts and brakes are reinstalled. A couple of electrical connectors need repairs and the diffs serviced with gear oil.
View attachment 419013

View attachment 419014
Along the way, I discovered a couple of new tools and ways to do things.
View attachment 419015

View attachment 419016

View attachment 419017

Setting the backlash and preload wasn’t as bad as I thought they’d be. It got easier and easier each time I rolled the carrier in and out. Documenting each change and the results is a must.

If I had to do it over again, I would have simply cleaned out all the metal chips, stuffed the diff back in its housing and waited till spring to regear. I would have made it to the New Year’s Run and a few other trails. That said, I’m glad for the experience and lessons learned.

Can’t wait to attend to the remaining details and finish the job. I’m looking forward to finding out how Gypsy performs with 4.88s and 35s.
Click to expand...
WJCO said:
Gears are a pain in the ass but rewarding to do it and appreciate what's involved.
Click to expand...
This is probably why they cost so much to have a shop do it. If I had nothing else going on I may have attempted mine myself but it doesn't look fun at all. Glad you got it all sorted out. I'm sure you'll be pleasantly surprised how it feels. I know after 5:13's on 37's it was great.
 
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