4.56 in my XJ - Dana 30 is being a PITA - JeepForum.com
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post #1 of 4 Old 10-04-2013, 08:29 AM Thread Starter
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1994 XJ Cherokee 
Join Date: Feb 2013
Location: Boulder
Posts: 39
4.56 in my XJ - Dana 30 is being a PITA

I'm installing my 4.56 gears in my XJ, D30 front and 8.25 rear.

8.25 went in fine, minus the notching of the pin. .005 and perfect pattern.

d30 went in fine using the short pinion gear set from a TJ, however, I can't get the ring gear to move in tight enough against the pinion. My preload is set perfect on the pinion and I pulled out the factory shims on the carrier to start setting my backlash. I shimmed it as much as i could on the left to get in in against the pinion but I still have a full dials movement on my dial indicator. (So much i didn't bother to record the amount)

Anyone run into this issue before? Do i need to go to a new carrier?


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post #2 of 4 Old 10-04-2013, 09:02 AM
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1998 ZJ 
Join Date: Mar 2006
Location: Helsinki, Finland - on the European side of the Atlantic
Posts: 8,649
D30 carrier break is at 3.73; if you had stock gears on an auto XJ you need a new carrier.

I'm wondering what year XJ you have since you're talking about TJ gear set.. only '00-'01 have low pinion axles, all others are high pinion.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

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post #3 of 4 Old 10-04-2013, 07:27 PM
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1984 CJ7 
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Location: Monument Colorado
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what Timo said plus this. Always check run out on a Dana 30 before you try to set it up. I have seen D30 run out vary from 6 thousandths to 2 thousandths just by clocking the ring around on the diff. D30s are kind of flimsy and flex more than anything else I ever setup.
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post #4 of 4 Old 10-07-2013, 08:48 PM Thread Starter
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1994 XJ Cherokee 
Join Date: Feb 2013
Location: Boulder
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Thanks guys, Swapped to a 3.73 and up carrier and all is well.
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