Same ring gear Bolts have broken twice??? - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 16 Old 03-26-2013, 04:38 PM Thread Starter
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Same ring gear Bolts have broken twice???

I had 5.13's installed 2 years ago on my stock carrier in my front Dana 30 and rear Dana 44. About 3 months ago, 2 ring gear bolts broke off on my rear 44. I got the rest of the bolt out and installed 2 new ring gear bolts from the dealership and torqued them down. Now, 3 months later, the SAME 2 ring gear bolts break again? At first, I thought it was bad ring gear bolts but now I wonder if it is a bad gear setup? Tell me what your thoughts. Thanks.

2008 Unlimited X
2" Synergy Hybrid Lift, 5.13's and 37's on 18's
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post #2 of 16 Old 03-26-2013, 04:52 PM
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Did you check the torque on all the bolts when you replaced the 2 broken bolts? The only thing I can think of is that the threads in the ring gears are just a hair larger than the others causing the bolts to snap under heating and cooling cycles.
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post #3 of 16 Old 03-26-2013, 05:10 PM Thread Starter
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Yup. I re-torqued all the bolts to spec (I think it is 80-90 ft. lbs.) when I reinstalled the new ones. It is just weird the same 2 broke again.

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post #4 of 16 Old 03-26-2013, 05:12 PM
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Looking at a clock for reference, what two broke. Check the depth of the holes, but, maybe two holes were slightly off and those two bolts are taking the majority of the torque?
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post #5 of 16 Old 03-26-2013, 05:23 PM Thread Starter
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So, are you guys thinking it is something to do with the ring gear bolts and torque and not the gear setup since I went 2 years without a problem? If so, I am going to go to the dealership tomorrow, pickup all new bolts and replace all them and torque them down to spec. Let me know your thoughts. Thanks!

2008 Unlimited X
2" Synergy Hybrid Lift, 5.13's and 37's on 18's
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post #6 of 16 Old 03-26-2013, 05:57 PM
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Maybe something wrong with the ring gear? The mating surface might not be perfectly flat. This is just a theory

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post #7 of 16 Old 03-26-2013, 07:18 PM Thread Starter
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Originally Posted by chknkatsu View Post
Maybe something wrong with the ring gear? The mating surface might not be perfectly flat. This is just a theory
That is a thought but, it seems like that would have been a problem from the start when the gears were installed 2 years ago?

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post #8 of 16 Old 03-28-2013, 01:41 PM
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I just drop my jk at tonny's hoyt 4x4 and he told me about a jk that broke the gears on the rear is that your jk by any chance???? he is doing the gears on mine too 2013 jku same color as the one in there (silver) OIIIIIIIO
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post #9 of 16 Old 03-28-2013, 01:57 PM
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What bolts are in your rear 44 gears? There are two different sizes, 1/2" and 7/16" currently out there. The 1/2" are torqued to 100 ft-lb per the factory service manual (FSM), the 7/16" are to 65 ft-lb per the FSM. I've seen the 7/16" ring gear bolts snap due to being torqued to the 1/2" spec.

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2007 2dr X, 6sp, 35's on D44's, 2" lift, cage, hydro, etc.
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post #10 of 16 Old 03-28-2013, 02:01 PM Thread Starter
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Originally Posted by superjeeps View Post
I just drop my jk at tonny's hoyt 4x4 and he told me about a jk that broke the gears on the rear is that your jk by any chance???? he is doing the gears on mine too 2013 jku same color as the one in there (silver) OIIIIIIIO
Yup, that is mine. Yesterday, I started replace the 2 broken ring gear bolts and all of the remaining ones with new ones and about 6 of the 10 sheared off when trying to remove them. So, I found out the problem was when my gears were originally installed, the ring gear bolts were torqued on too tight. I removed and seperated the carrier and ring gear from the housing but could not extract what was left of 4 bolts in the ring gear and called it quits. Hoyt 4x4 is going to put new gears in the rear for me. I should have had them do the front and rear originally and I would probably not be having this problem.

2008 Unlimited X
2" Synergy Hybrid Lift, 5.13's and 37's on 18's
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post #11 of 16 Old 03-28-2013, 02:08 PM Thread Starter
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Originally Posted by JKred07 View Post
What bolts are in your rear 44 gears? There are two different sizes, 1/2" and 7/16" currently out there. The 1/2" are torqued to 100 ft-lb per the factory service manual (FSM), the 7/16" are to 65 ft-lb per the FSM. I've seen the 7/16" ring gear bolts snap due to being torqued to the 1/2" spec.
I am pretty sure mine are 1/2" bolts, at least the new ones I got from the dealership were. My original bolts were part of a master install kit and I believe they were the same size.

2008 Unlimited X
2" Synergy Hybrid Lift, 5.13's and 37's on 18's
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post #12 of 16 Old 03-28-2013, 02:32 PM
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wow brother that sucks when you take your jeep to a place and they do a bad job but what can you do!!! I think gears and tranny are the only thing I don't know how to do that's way I took it to tonnys !!! I am doing just the rear because I don't have all the money to do front and rear at the same time so I took the front drive shaft out and after jeep beach I will do the front hehe I hope to win some lockers so I can save some money hehe!!!!! good luck with the heep and I hope he can take the broken bolts out the housing so you don't have to spend more cash!!!
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post #13 of 16 Old 03-28-2013, 04:33 PM Thread Starter
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Thanks, man. That is exactly like me as transmission internals scare me and I have seen gears changed plenty of times but it is something I would rather a pro do. I know tony will do a good job from all the positive feedback I have read.

2008 Unlimited X
2" Synergy Hybrid Lift, 5.13's and 37's on 18's
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post #14 of 16 Old 03-29-2013, 12:21 PM
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Quote:
Originally Posted by JKred07 View Post
What bolts are in your rear 44 gears? There are two different sizes, 1/2" and 7/16" currently out there. The 1/2" are torqued to 100 ft-lb per the factory service manual (FSM), the 7/16" are to 65 ft-lb per the FSM. I've seen the 7/16" ring gear bolts snap due to being torqued to the 1/2" spec.
Dont know where you found the 100 ft-lb spec.
I use 135 on jk 1/2 bolts
Alldata, "Differentials" manule by jim allen & randy lyman, Dana Spicer & Drivetrain Direct all state 135 lbs

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post #15 of 16 Old 03-29-2013, 01:31 PM
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Quote:
Originally Posted by tweba08 View Post
Yup, that is mine. Yesterday, I started replace the 2 broken ring gear bolts and all of the remaining ones with new ones and about 6 of the 10 sheared off when trying to remove them. So, I found out the problem was when my gears were originally installed, the ring gear bolts were torqued on too tight. I removed and seperated the carrier and ring gear from the housing but could not extract what was left of 4 bolts in the ring gear and called it quits. Hoyt 4x4 is going to put new gears in the rear for me. I should have had them do the front and rear originally and I would probably not be having this problem.

Are you going to have them check the front bolts too ?

Whoever did the rear wrong did the front the same way (over torqued) most likely.

.

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post #16 of 16 Old 03-29-2013, 01:42 PM Thread Starter
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Originally Posted by kaptkrappy View Post
Are you going to have them check the front bolts too ?

Whoever did the rear wrong did the front the same way (over torqued) most likely.

.
Actually, the guy that originally did the gears told me that he installed the rear himself and he had his father in law install the front. I am already into this for way more $ than expected since the gears weren't installed right in the rear the first time, so I am going to hope the front is fine.

2008 Unlimited X
2" Synergy Hybrid Lift, 5.13's and 37's on 18's
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