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..."
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.
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.
Front Pinion Bearings for XJ 1984 to 1996 are the following part numbers:
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.