Dunedog's gear swap

[LiftedAWDAstro]

Today's class will be on swapping from 3.42 to 4.10 gears in a 1999 AWD Astro. Jim has so graciously donated his van (and the cash ) to do this project.

Let's start with the front diff. I had a spare one that Jim bought so I am doing it a day before he arrives.

First I started with wire brushing the outside of the diff to get most of the crud off it.



Crack the case in half and clean it out real good. I removed the pinion and bearing races to install new ones.



Here is the clamshell bearing puller I will use to get one of the bearings off the pinion. This will be important because I will need to install shims under this bearing to get the proper pinion depth. I don't have a pinion depth tool so it will be trial and error.



Of course Jim so graciously bought all new gears and install kits...




More after I get more work done. Coming up will be pressing in new pinion bearing races, pressing on the bearings and shims on the pinion and pressing new bearings on the carrier after I put the new ring gear on. Stay tuned...

[GEJ]

I would be willing to bet Jim won't have to use his headlights on the way back home.His smile will be so big from the difference it will light up the 90 all the way all on it's own.

[astrozam]

Cool, its been awhile since we had Sunday school,lol

Keep the pics comin boys

[LiftedAWDAstro]

Use a brass drift to pound in the new pinion bearing races... (don't forget safety glasses)



Install the pinion with the new bearings using the original shim. Do not install the crush sleeve or seal yet...



Put some marking compound on 3 or 4 teeth on 2 sides of the ring gear. You then assemble the whole diff and torque everything down. Then spin the pinion over by hand in both directions 4 or 5 turns. You then disassemble the whole thing to check the gear pattern on the ring gear.

[LiftedAWDAstro]

Forgot to get pics...install the new ring gear on the carrier and use locktite on the bolts and tighten to 55 ft-#.

Here is about the 3rd or 4th test fit...The pinion has 0.034" shim and the carrier and pinion preloads are set. The carrier is set 1 notch towards the pinion from stock. This is the resulting pattern.







Tune in tomorrow as I finish up the front diff.

[Smiliesafari]

Pattern looks about perfect.

[dunedog]

all this and Lynne's cookin'too, for a suitcase of Pabst's ....life is good!!!

[LiftedAWDAstro]

Pattern looks about perfect.

I am thinking the same thing! Tomorrow I will button it up and post more pics. I will include detail pics of the carrier bearing adjusters and the crush sleeves.

all this and Lynne's cookin'too, for a suitcase of Pabst's ....life is good!!!

Yeah...she made Lasagna for dinner tomorrow night and she made a double batch of peanut butter cookies too!

[snapple]

all this and Lynne's cookin'too, for a suitcase of Pabst's ....life is good!!!

Yeah...she made Lasagna for dinner tomorrow night and she made a double batch of peanut butter cookies too!

MMMMM .....Lasagna & PBR!

[T.Low]

all this and Lynne's cookin'too, for a suitcase of Pabst's ....life is good!!!

Yeah...she made Lasagna for dinner tomorrow night and she made a double batch of peanut butter cookies too!

MMMMM .....Lasagna & PBR!

And 4:10s! You guys know how to have a good time!

[Cobra]

lifted you da man

and dunedog i can't believe it but twice in one month

You inspire me

[snapple]

I just scored a 4.10 ring & pinion for my front diff. on ebay!
So far,I've got that coming.Also have a Auburn locker and r&p for my
Now I just need to get my install kits!

[astrozam]

Well Jim, you picked about the best place you could go for great help and great eating, have fun with the new gear set.

Nice work & pics Dean

[T.Low]

lifted you da man

and dunedog i can't believe it but twice in one month

You inspire me

Yeah, DuneDude's been BUSY!

I wish I lived a little closer to Dr Lifted. After watching Jim with that sawzall its probably a good thing to not be his neighbor with an Astro! After 20 hours strait of sawzalling he might walk up to the wrong van and fire that thing up!

[skippy]

Nice write up Dean , good luck guys . Jim your gonna LOVE the 4.10's !!!!



And heres waving back at ya as you pass on by , as i've said your welcome to stop in for coffee if i'm home as you come through . i'm literally 2 minutes off exit 25 on the NYS thruway .