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I finished my 3.75 swap today, it only took about 10 hours
I bought extra carrier bearings, and a pinion bearing. Honed them out for a slip fit so the shims can be swapped out without destroying the bearing. That took a long time, went from .016 to .047 in .004 increments, then changing backlash and carrier preload as the pinion was moved toward the ring gear.
When the right shims are found the new bearings get pressed on.
To make matters confusing I ordered the wrong installation kit. It was for an early dana 36, I have a 1993. It has some different shims, different carrier bearing cups, bigger axle bearings. Got lucky and had shims from other set ups, reused the axle bearings. Bought new cups.
Got the speedo gears swapped out.
Now I just need to put it in the car.
Looks god to me. I understand all the principles and steps and I have even been there when one was done but I personally dont think I will ever tackle it by myself. I do all my own work on my '85 but I just dont think I have the skill set for this advanced procedure. Maybe IF I had all the correct tools and someone with the knowledge right beside me. I applaud you sir!
I forgot to mention...I wouldn't recommend anyone doing this, it's such a big PITA. I just don't know anyone I trust around here, otherwise I'd pay a shop. I know a guy who payed a shop to do it twice, the first time it failed. And that was on a simple old GM 10 bolt.
I've done it on a few Ford 8.8s. I don't consider it an exceptionally difficult job but it is time consuming and requires some tools most people don't have. Hell of an idea oversizing some extra bearings. I'll remember that if I ever do another R&P.
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Any diy'er do a gear swap?
