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Dana 30 front axle

UNDER CONSTRUCTION....
 
 
Parts List
 
Below is an exploded view of a Dana 30 front axle, the parts list is shown as a cherokee but most parts are the same as wranglers and some grand cherokee's.   These are the best and most complete parts lists I can find for the moment, if I can find a better picture with a parts list I will change it.   The "Model 30 Front Axle" listed directly below is shown as a passenger side drop, most late model Jeeps will have a drivers side drop but for parts references they are similar.
  
 
 
Item Description
1
Outer axle dust shield (1985-00 XJ Cherokee)
2
Spicer axle shaft universal joint per axle, non-greaseable style (1985-94 XJ Cherokee, 1992-94 Grand Cherokee)4
2
Spicer axle shaft universal joint per axle, greaseable style (1985-94 XJ Cherokee, 1992-94 Grand Cherokee)4
2
Spicer axle shaft universal joint per axle, non-greaseable style (1995-00 XJ Cherokee, 1995-98 Grand Cherokee)5
3
Inner axle dust shield (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
4
Inner axle shaft seal (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
5
Collapsible pinion spacer (2000 XJ Cherokee, 1996-01 Grand Cherokee)1 ,3Not Shown
6
Outer pinion bearing set, Includes 1 bearing and 1 cup (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
7
Outer pinion oil slinger (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
8
Pinion oil seal (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
9
Pinion yoke strap and bolt style; strap and bolts not included (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
9
Pinion yoke u-bolt type; u-bolts not included (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
9A
Pinion yoke u-bolt kit, per yoke (for yoke Part #248091X)
9B
Pinion yoke strap and bolt kit, per yoke (for stock yoke & part #2465611)
10
Pinion nut washer (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
11
Pinion nut (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
12
Axle shaft assembly driver side with ABS (1992-00 XJ Cherokee, 1992-98 Grand Cherokee)
12
Axle shaft assembly driver side without ABS (1985-00 XJ Cherokee)
12A
Outer axle shaft without ABS (1985-94 XJ Cherokee)6
13
Standard differential gear set, Includes #24 & ten of #19 (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
13A
Differential side gear thrust washer, 2 required (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
14
Axle shaft assembly passenger side with ABS (1992-00 XJ Cherokee, 1992-98 Grand Cherokee)
14
Axle shaft assembly passenger side without ABS (1985-00 XJ Cherokee)
14A
Outer axle shaft without ABS (1985-94 XJ Cherokee)6
15
Inner pinion bearing baffle (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
16
Pinion and differential bearing shim kit, Includes # 16, 10, 11, 16 & pinion preload shims (1985-00 XJ Cherokee)2
16
Pinion and differential bearing shim kit, Includes #16, 10, 11, 16 (2000 XJ Cherokee, 1992-98 Grand Cherokee)1
17
Inner pinion bearing set, Includes 1 bearing & 1 cup (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
18
Inner pinion oil slinger (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
19
Ring gear bolt, 10 required (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
20
Ring and pinion (3.07 ratio) 43-14 TEETH, Includes #6,7,8,10,11,15,16,17,18,19 & 24 (1985-00 XJ Cherokee)2
20
Ring and pinion (3.54 ratio) 39-11 TEETH, Includes #6,7,8,10,11,15,16,17,18,19 & 24 (1985-00 XJ Cherokee)2
20
Ring and pinion (3.73 ratio) 41-11 TEETH, Includes #6,7,8,10,11,15,16,17,18,19 & 24 (1985-00 XJ Cherokee)2,7
20
Ring and pinion (4.10 ratio) 41-10 TEETH, Includes #6,7,8,10,11,15,16,17,18,19 & 24 (1985-00 XJ Cherokee)2,7
20
Ring and pinion (4.56 ratio) 41-9 TEETH, Includes #6,7,8,10,11,15,16,17,18,19 & 24 (1985-00 XJ Cherokee)2,7
20
Ring and pinion (4.88 ratio) 39-8 TEETH, Ring & Pinion only (1985-00 XJ Cherokee)2,7
20A
Ring and pinion installation kit for 4.88 ratio Includes #5,6,8,10,11,16,17,19,22 & 24 & gear marking compound (1985-00 XJ Cherokee)2
20
Ring and pinion (3.07 ratio) 43-14 TEETH, Includes #5,6,7,8,10,11,15,16,17,18,19 & 24 (2000 XJ Cherokee)1,8
20
Ring and pinion (3.55 ratio) 39-11 TEETH, Includes #5,6,7,8,10,11,15,16,17,18,19 & 24 (2000 XJ Cherokee, 1996-98 Grand Cherokee)1,3, 8
20
Ring and pinion (3.73 ratio) 41-11 TEETH, Includes #5,6,7,8,10,11,15,16,17,18,19 & 24 (2000 XJ Cherokee, 1996-98 Grand Cherokee)1,3,8
20
Ring and pinion (4.10 ratio) 41-10 TEETH, Includes #5,6,7,8,10,11,15,16,17,18,1 9& 24 (2000 XJ Cherokee, 1996-98 Grand Cherokee)1,3,8
20
Ring and pinion (4.56 ratio) 41-9 TEETH Ring & Pinion only (2000 XJ Cherokee, 1996-98 Grand Cherokee)1,3, 8
20
Ring and pinion (4.88 ratio) 39-8 TEETH, Ring and Pinion only (2000 XJ Cherokee, 1996-98 Grand Cherokee)1,3, 8
20A
Ring and pinion installation kit for 4.56 & 4.88 ratio, Includes #5,6,8,10,11,16,17,19,22 & 24 & gear marking
compound (2000 XJ Cherokee, 1996-98 Grand Cherokee)1,3
21
Standard differential case (3.07-3.55 ratio), Includes #24, ten of #19, & carrier shim kit (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
21
Standard differential case (3.73-4.88 ratio), Includes #24, ten of #19, & carrier shim kit (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
22
Differential carrier bearing set, Includes 2 bearings & 2 cups (1985-00 XJ Cherokee, 1992-01 Grand Cherokee)
23
Outer axle shaft with ABS (1995-00 XJ Cherokee, 1995-98 Grand Cherokee)
24
Differential cover gasket (1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
25
Differential cover bolt (Qty. as needed) 1985-00 XJ Cherokee, 1992-98 Grand Cherokee)
26
Stainless steel differential cover, Includes bolts and gasket (1985-00 X Grand Cherokee)2Not Shown
26
Stainless steel differential cover, Includes bolts and gasket (2000 XJ Cherokee, 1992-98 Grand Cherokee)1
27
RTV silicone, 3 oz. Tube, for use as a gasket Not Shown
  1 - not for 2000 XJ Bill of Material #610976 & 610977 5 - 1.18" bearing cap diameter
  2 - Only for 2000 XJ with Bill of Material #610976 & 610977 6 - Uses 260X type universal joint
  3 - Only for 1996 ZJ Bill of Material #610572 & 610573 7 - These ring and pinions are reverse rotation
  4 - 1.06" bearing cap diameter 8 - These ring and pinions are standard rotation
 
 
 
Item Description
1
Axle shaft assembly passenger side outer, without ABS, Includes #36 bushing installed (1984-91 XJ Cherokee)2
1A
Outer axle shaft without ABS (1984-91 XJ Cherokee)3
2
Axle shaft seal passenger side (1984-91 XJ Cherokee)
3
Axle shaft passenger side inner (1984-91 XJ Cherokee)
4
Standard differential gear set (1984-91 XJ Cherokee)
4A
Differential side gear thrust washer, 2 required (1984-91 XJ Cherokee)
5
Differential carrier bearing set, Includes 2 bearings & 2 cups (1984-91 XJ Cherokee)
6
Pinion and differential shim kit, Includes #19, #20, all parts in #6 & RTV silicone (1984-91 XJ Cherokee)
7
Ring gear bolt, 10 required (1984-91 XJ Cherokee)
8
Standard differential case (2.73-3.54 ratio,) Includes #9, carrier shim kit & #7 (1984-91 XJ Cherokee)
8
Standard differential case (3.73-4.88 ratio,) Includes #9, carrier shim kit & #7 (1984-91 XJ Cherokee)
9
Differential cover gasket (1984-91 XJ Cherokee)
10
Ring and pinion (3.07 ratio) 43-14 TEETH, Includes #6,7,9,11,12,13,15,16,17,19 & 20 (1984-91 XJ Cherokee)4
10
Ring and pinion (3.54 ratio) 39-11 TEETH, Includes #6,7,9,11,12,13,15,16,17,19 & 20 (1984-91 XJ Cherokee)4
10
Ring and pinion (3.73 ratio) 41-11 TEETH, Includes #6,7,9,11,12,13,15,16,17,19 & 20 (1984-91 XJ Cherokee)4
10
Ring and pinion (4.10 ratio) 41-10 TEETH, Includes #6,7,9,11,12,13,15,16,17,19 & 20 (1984-91 XJ Cherokee)4
10
Ring and pinion (4.56 ratio) 41-9 TEETH, Includes #6,7,9,11,12,13,15,16,17,19 & 20 (1984-91 XJ Cherokee)4
10
Ring and pinion (4.88 ratio) 39-8 TEETH, Ring and pinion only4
10A
Ring and pinion installation kit for 4.88 ratio, Includes #5,6,7,8,9,10,11,16,17,19,20
& gear marking compound (1984-91 XJ Cherokee)
11
Inner pinion oil slinger (1984-91 XJ Cherokee)
12
Inner pinion bearing set, Includes 1 bearing & 1 cup (1984-91 XJ Cherokee)
13
Inner pinion bearing baffle (1984-91 XJ Cherokee)
14
Inner axle shaft seal driver side (1984-91 XJ Cherokee)
15
Outer pinion bearing set, Includes 1 bearing & 1 cup (1984-91 XJ Cherokee)
16
Outer pinion oil slinger (1984-91 XJ Cherokee)
17
Pinion oil seal (1984-91 XJ Cherokee)
18
Pinion yoke u-bolt type, u-bolts not included (1984-91 XJ Cherokee)
18
Pinion yoke strap and bolt type, strap and bolts not included (1984-91 XJ Cherokee)
18A
Pinion yoke u-bolt kit, per yoke (for yoke #248091X)
18B
Pinion yoke strap and bolt kit, per yoke (for yoke #2465611)
19
Pinion nut washer (1984-91 XJ Cherokee)
20
Pinion nut (1984-91 XJ Cherokee)
21
Spicer axle shaft universal joint, per axle, non-greaseable style (1984-91 XJ Cherokee)1
21
Spicer axle shaft universal joint, per axle, greaseable style (1984-91 XJ Cherokee)1
22
Axle shaft assembly driver side without ABS (1984-91 XJ Cherokee)2
23
Stainless steel differential cover, Includes bolts & gasket (1984-91 XJ Cherokee)
24
Front axle disconnect shift fork collar (1984-91 XJ Cherokee)
25
Front axle disconnect shift fork (1984-91 XJ Cherokee)
26
Front axle disconnect servo motor retaining clip (1984-91 XJ Cherokee)
27
Front axle disconnect shift fork insert, 2 required (1984-91 XJ Cherokee)
28
Front axle disconnect servo o-ring (1984-91 XJ Cherokee)
29
Differential cover bolt, quantity: as needed (1984-91 XJ Cherokee). Not Shown
30
Front axle disconnect motor assembly, Includes gasket #34,
fork retainer clips, cover bolts & washer (1984-90 XJ Cherokee)
30
Front axle disconnect motor assembly (1991 XJ Cherokee)
31
Front axle disconnect housing cover (1991 XJ Cherokee)
32
Front axle disconnect switch assembly (1991 XJ Cherokee)
33
Front axle disconnect shift fork snap ring (1984-91 XJ Cherokee)
34
Front axle disconnect cover gasket (1984-91 XJ Cherokee)
35
Inner bushing/bearing (1984-89 XJ Cherokee)
35
Inner bushing/bearing (1990-91 XJ Cherokee)
36
Outer bearing (1984-89 XJ Cherokee)
36
Outer bushing (1990-91 XJ Cherokee)
 

1 - 1.06" bearing cap diameter

2 - Non CV-type axle shaft assemblies

3 - Uses 260X type universal joint

4 - These ring and pinions are reverse rotation

 
 

Dana 30 Specs.
 
Dana 30 - Front Axle 
Ring Gear Size:
7.2" (7 1/5")
Reverse Cut Ratios: 3.07, 3.54, 3.73, 4.10, 4.56, 4.88
Gears Ratios Available: 3.07, 3.31, 3.54, 3.55, 3.73, 4.10, 4.27, 4.56, 4.88, 5.38
Locker Options: ARB, Detroit, Lock-Right, Powr Lok, TrueTrac, Aussie, E-Locker
Cases/Carriers:
  • 3.54 & Down Standard
  • 3.73 & Up Standard
  • 3.73 & Up Powr Lok

Dana 30s feature an open knuckle design with 7 1/5" ring gear. Although the same model axle has been used for almost 25 years, they are not compatible. There are numerous various brakes, hubs, differential orientation, wheel bolt pattern, and width.

A strength of the YJ Dana 30 is its use of reverse cut ring and pinion. The ring and pinion are stronger when they are reverse cut in front axles. The reverse cut axle also provides better ground clearance and driveline angles.

Unfortunately, the TJ does not use the reverse cut Dana 30. It uses a normal cut Dana 30 similar, but not compatible to, the CJ Dana 30.

The YJ and the TJ Dana 30 uses the 5 on 4.5" wheel bolt pattern. The YJ Dana 30 is of course set up for leaf springs and the TJ Dana 30 is set up for coil springs.

The Comanche (MJ) and Cherokee (XJ) use a reverse cut Dana 30 and the Grand Cherokee (ZJ) uses a normal cut Dana 30. Like the YJ and the TJ, these axles use a 5 on 4.5" wheel bolt pattern. All of these trucks use coil springs up front.

The Dana 30 front axle was used for a short time from 1971-1973 in Cherokees (SJ), Wagoneers (SJ), and J-Series pickups.

 
Model/Version
Spring Pads
Wheel to Wheel
 Years
Dana 30/CJ Narrow Track
28"
53"
'72-'81
Dana 30/CJ Wide Track
28"
56"
'82-'86
Dana 30/XJ
n/a
60 3/4"
'84-
Dana 30/MJ
n/a
n/a
'86-'92
Dana 30/YJ
31"
60"
'87-'95
Dana 30/ZJ
n/a
n/a
'93-
Dana 30/TJ
n/a
n/a
'97-

 

 

 

 

Assembly Specifications
Cover Bolt Ft. Lbs. 30-40
Pinion Brg. Preload In. Lbs 20-40
Pinion Nut Ft. Lbs. 200-220
Ring Gear Backlash 005-.009
Ring Gear Bolt to case Ft. Lbs. 45-60
Side Brg. Caps Ft. Lbs. 35-50

 

 

 

This is a list of common fluids you will need when servicing your Jeep's Transmission, Transfer Case or Differentials.

Dana 30 & Dana 44 Differentials
SAE 80W-90 GL5 Gear Oil
NV3550 Manual Transmission
Mopar NV3550 Transmission Fluid
Synchromesh
Redline MT-90
AX-15 Manual Transmission
Mopar AX-15 Transmission Fluid
Redline MT-90
NP-231 Transfer Case
ATF+3

 


 

 

Dana 30 ID


 
Dana 30 front 10 bolt cover Round with flattened vertical cover sides. 7.56 inches Threaded plug to fill differential with oil.
 
 
The Ring and Pinion tag is located on the left vertical bolts of the diff. cover.
 

Pinion

 Most Dana 30 axles come in a reverse cut High Pinion (HP - on the right side of the picture) or a normal cut Low Pinion (LP - on the left side of the picture), the High Pinion is the desired axle for most off roaders as it keeps the drive shaft up higher and out of harms way.  
 
The Dana 30 yoke (disconnect part #18 on the above part list / non-disconnect #9) The yoke is held in place with a pinion nut (disconnect part #19 / non disconnect #11) and threaded onto the Pinion gear (disconnect part #10 / non disconnect #20).   The U-joint is held in place using 8mm threaded bolts or ubolts that use an 8mm nut.
 
 
A pinion trail repair kit (below)  inclused - U/Joint, pinion seal, U/Bolt or strap kit, pinion nut, and pinion nut washer
 
 
There are two types of devices used to hold a drive shaft ujoint inplace to a pinion yoke.
 
The strap style holds the ujoint to the pinion yoke by screwing a bolt into threads on the yoke. (disconnect part #18b / non disconect #9b)
 
The Uboltkit retains the u-joint by using a threaded ubolt that passes through the yoke and clamps down onto the other side of the yoke using a washer and nut.  (disconnect part # 18a / and non disconnect #9a )  This style is stronger than the ujoint strap above and can be changed by picking up a new pinion that is not threaded and using the ubolt kit.   (for a 1310 ujoint the Spicer part number is: 2-94-28x
 
 
 
Replacing your Pinion Seal
 
Pinion Seal
pictures from MadXj.com
 
Other side of Pinion Seal and the washer that is seated behind the bearings.
 
pictures from MadXj.com
 
Dana 30 with pinion seal removed
 
pictures from MadXj.com
 
REMOVAL  (from manual)
1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Mark the propeller shaft yoke and pinion yoke for installation alignment reference.
(4) Remove the propeller shaft from the yoke.
(5) Remove the pinion yoke nut and washer. Use Remover C—452 and Wrench C—3281 to remove the pinion yoke.
(6) Mark the positions of the yoke and pinion gear for installation alignment reference.
(7) Use Remover 7794A and slide hammer to remove the pinion gear seal.

INSTALLATION  (from manual)
(1) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer D—163 and Handle C—4171.
(2) Align the reference marks and install yoke on the pinion gear with Installer W—162—D.
(3) Install a new pinion nut on pinion shaft, lighten the nut to 217—352 N.m (160—260 ft. lbs.).
(4) Align the installation reference marks and attach the propeller shaft to the yoke.
 
 

 Inner Axle Seals
 
(non disconnect part # 3 and 4)
 
A bad chewed up Inner axle seal.
pictures from Stu-Offroad.com
 
Removal:  Several methods can be used for hard to remove seals, but as show below the long pipe methods works well with little damage.
 
pictures from Stu-Offroad.com
 
 
 
Installing new seals can be done by using a simple home made tool picures below.  (bc4x4.com)
 

Parts required:

  • 12 inches of 1/2" inch ready rod (allthread) or equivalent
  • 2 - 7/8" flat washers
  • 3 - 1/2" inch flat washers
  • 2 - 12 mm flat washers (optional)
  • 3 - 1/2" inch nuts
  • 2 - axle seals

 
 
Insert with nuts close together on the allthread with enough room to position one end of the allthread in at a time and then center the allthread up to start turning the nuts to push the seals into place in the axle.
 
 
Back off the nuts enought to remove the allthread and remove seal tool, inspect seals.
 
 

 Dana 30 Axle Shafts and U-Joints
 
Pass. Side Axle Shaft
 
 
The Dana 30 shaft has a 27 spline count and has a 1.16" in diameter.
 
 
 
 
 The YJ Dana 30 uses an axle disconnect system that is prone to failure. Often the vacuum hoses that activate the disconnect system will fall off or tear. Sometimes the vacuum motor won't have enough power to engage the sleeve when the gear lube in the disconnect housing gets gummed up. Another problem is that since only one axle is ever disconnected, an automatic locker or limited slip differential can cause problems with the axle and with handling. The drivers side axle is always spinning the differential.
 
 
 
 
 
 
 
 
 
 
The 260 u-joint (SPICER part # 5-260x) is used on early model Jeeps without ABS, the 297 (SPICER part # 5-297x) later replaced by the 5-760x u-joint is used on ABS Jeeps and late model Jeeps and is much stronger than the 260 u-joint.
 
 
Below is a 260 on the left and a 760 on the right.
 
 
 
 5-297x (and 5-760x)
Journal & Bearing Kits - Isr Style Model/Part #:  5-297X
K1 SNAP RING DIM. 2.1880
D1 BEARING CAP DIA. 1.1880
K2 SNAP RING DIM. 2.1880
D2 BEARING CAP DIA. 1.1880
 
5-260
Journal & Bearing Kits - Isr Style Model/Part #:  5-260X
K1 SNAP RING DIM. 2.1880
D1 BEARING CAP DIA. 1.0620
K2 SNAP RING DIM. 2.1880
D2 BEARING CAP DIA. 1.0620
 
 

Dana 30 Wheel Bearing

 
The front wheel bearings are incorporated into a one piece hub assembly which takes special tools to take apart. For most of us, this hub assembly is a non-serviceable part. I took the easy way out and purchased a new hub assembly from the local auto parts store. 
 
 
Here is a picture of one of a wheel bearings that has well exceeded its life.
 
 
Step 1.
Remove the caliper bolts
 
 
Step 2.
Remove the cotter pin from the end of the axle, TOSS IN THE GARBAGE!... do not re-use an old cotter pin!
 
 
Step 3.
With an impact or large wrench and breaker bar remove the axle nut, this is a 36mm nut.
 
 
Step 4.
There are three bolts that hold the wheel bearing hub assembly to the steering knuckle. The heads on these have 12 points so you need to use a 12 point wrench to remove them.  Use a 12 point, 13mm socket wrench to remove the 3 bolts. 
 
 
Optional Step.
If the wheel bearing doesnt come lose with a hammer it may be stuck... this happens quite often in our area.   Use a 2.5-3" bolt with a nut on the end and hex head.   Turn the wheel to the right to make room to slide the bolt in behind the ear of the stub shaft and the axle housing.   Having another person slowly turn the wheel to the left to hold the bolt in place, remove your hands from the axle and turn the wheel to the left untill the wheel beating falls off.  
 
 
Step 5.
Remove the Wheel Bearing
 
 
Step 6.
Reverse the steps as you put the new wheel bearing on, cleaning up and prepping any surfaces that may have caused the wheel bearing to
 
 
Step 7.
Torque the nut to 175 ft. lbs. - this may require you to lower the jack enough to get the other tire on the ground or even lock in it 4low.
 
 
Step 8. & 9.
Reinstall the disk, the caliper, retainer plate, and put a NEW cotter pin back in.
 
 
 
 

 

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