Spartan Pops all the time in 4wd -
LinkBack Thread Tools
post #1 of 6 Old 01-28-2014, 09:43 AM Thread Starter
Registered User
1995 XJ Cherokee 
Join Date: Dec 2013
Location: Chattanooga
Posts: 11
Spartan Pops all the time in 4wd

So I bought a Spartan for my XJ Put it in the Dana 30 up front and did a complete over haul. New bearings, axles, ball joints, whole nine yards. This over haul became, "since Im here Ill put a locker in."

So under power in 4wd, this thing sounds like a broke ring gear popping. Coast its quiet. Turning it releases like it should. Do the spin test. Can put resistance on one wheel and it ratchets. 2wd can hear it if you want to, and pops when turning like a ratchet locker will.

Biggest thing is the popping in 4wd. Wheels straight, slow or fast, wheels turned, still does it. Put it in 2wd, no popping.

Im at a loss.. Never ran one before. Looking at a "hey dummy you forgot to..."

YardFab is offline  
Sponsored Links
post #2 of 6 Old 01-28-2014, 02:13 PM
Registered User
1984 CJ7 
Join Date: May 2008
Location: Monument Colorado
Posts: 5,840
what could that be but the teeth in the locker slipping past each other while it is engaged?
foggybottombob is offline  
post #3 of 6 Old 01-29-2014, 02:23 PM Thread Starter
Registered User
1995 XJ Cherokee 
Join Date: Dec 2013
Location: Chattanooga
Posts: 11
No idea.. I pulled it apart again last night. everything looks good. Im going to start over and check back lash, mesh, whole thing over. Something not right for sure. I checked the spacing on the locker and its right on the money. Drove it in the snow last night in 4 hi and you would have thought it was going to explode. Confused as to what it is. Axle shaft, joints, hubs, bearings , locker , carrier , all literally new. Starting to wonder if its something to do with the Spartan itself.
YardFab is offline  
post #4 of 6 Old 01-29-2014, 03:33 PM
Registered User
2001 XJ Cherokee 
Join Date: Sep 2010
Location: Finleyville
Posts: 3,334
Hows your transfer case and front driveshaft joints?

Im the guy who makes new gauges, check out our gallery at
Azzy is offline  
post #5 of 6 Old 01-29-2014, 09:36 PM Thread Starter
Registered User
1995 XJ Cherokee 
Join Date: Dec 2013
Location: Chattanooga
Posts: 11

Got it figured out tonight... The bearing kit for the diff rebuild had the wrong inner bearing and race. From yoke I had no movement. Pinion depth was good , lash was good, and pattern was good. Found it by putting jeep on stands and removed diff covers and watched the rotation of pinion and ring gear. As soon as force was applied to the front tires, the pinion would start to deflect and pop. So.. went back to parts store handed them the bearing and race, and they apologized for the mistake.

Also found that the CV part of my drive shaft had some issues. The center ball and cup was dry as a bone.. it was binding and popping also ((not the same noise or as loud. you had to be under Jeep to hear it.)). So there were two problems.

Brand :National
Front Pinion Bearings for XJ 1984 to 1996 are the following part numbers:

Brand: National
Pinion Seal
5788 ( Fit Dana 44 rear and Dana 30 front housings)

I hope this helps someone in the future.
The inner bearing on some xj dana 30 use the same inner and outer bearing and race.
YardFab is offline  
post #6 of 6 Old 01-30-2014, 04:09 AM
Web Wheeler
Timo_90xj's Avatar
1998 ZJ 
Join Date: Mar 2006
Location: Helsinki, Finland - on the European side of the Atlantic
Posts: 8,712
..I would've also asked for a new set of R&P in compensation, since if the gear mesh is all messed up under torque, the R&P can be ruined pretty damn quickly.

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,...

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

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

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
Timo_90xj is online now  

Quick Reply

Register Now

In order to be able to post messages on the forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome