Rear differential bad..?
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Joined: Oct 2017
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Rear Differiancial Bad
Sorry I have no pictures, but every tooth on every spider gear in my 2006 Dana 60 was chipped off we filled a Dixie cup with the pieces, but I could still drive the van and it only ground off more bits and pieces when I took turns. Sharp slow circles seemed like it would bow up, but it went straight just fine. The ring gear showed no chips as well as a nice looking pinion gear. The first two C CLIPS to fall out missed everything and just landed above pinion gear bearing. But the 3rd. C CLIP must have been the one that fell into the spider gears. Does anyone know what the smoking gun might be that could let the drivers side spider gear to move left and allow three C CLIPS to fall out.???
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Cargo Master
Joined: Apr 2013
Posts: 3,087
Likes: 24
From: Central Florida
I understand that anything CAN happen, but I believe my technician friend was making a claim as to what usually happens. I’m not saying he’s right, I’m just saying it sounds right. If lots of people here have experienced catastrophic failures then I’ll adjust my opinion. 
and i recently read that backlash specs range about 10 thousandths. Give or take.
Thinking of this has me reflecting back to when they showed me the backlash. Going by my crappy memory I’d say it woulda/coulda been easily 4-5 times that. But when I saw it, I thought it was OK.
and i recently read that backlash specs range about 10 thousandths. Give or take.
Thinking of this has me reflecting back to when they showed me the backlash. Going by my crappy memory I’d say it woulda/coulda been easily 4-5 times that. But when I saw it, I thought it was OK.
Cargo Master
Joined: Jul 2003
Posts: 2,328
Likes: 14
From: Colorado
Have you checked your tailhousing for deflection? At 213k my driveshaft will deflect 1/4" by hand, causing a vibration at 84mph.
If you're gonna find a junkyard axle, be sure to get 4.10's, you will be amazed the difference.
No, if you change gear ratio you WILL need a tuner to correct the speedo. When I went from 3:73 to 4.10's my speedo was off by 11mph at 75.
I went from 225 tire to 245 tires and at 6000ft elevation and my normal work gear it was a dog. I did 4.10's and a SCT x4 tuner with mikes 5 star tunes and wow what a noticeable difference! I drive a lot of interstate driving and the 4.10's are great for power. I can holeshot night and day difference, putting a lot of people to shame in a 6500lb work van with ladders on top!
If you're gonna find a junkyard axle, be sure to get 4.10's, you will be amazed the difference.
No, if you change gear ratio you WILL need a tuner to correct the speedo. When I went from 3:73 to 4.10's my speedo was off by 11mph at 75.
I went from 225 tire to 245 tires and at 6000ft elevation and my normal work gear it was a dog. I did 4.10's and a SCT x4 tuner with mikes 5 star tunes and wow what a noticeable difference! I drive a lot of interstate driving and the 4.10's are great for power. I can holeshot night and day difference, putting a lot of people to shame in a 6500lb work van with ladders on top!
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Cargo Master
Joined: Apr 2013
Posts: 3,087
Likes: 24
From: Central Florida
Have you checked your tailhousing for deflection? At 213k my driveshaft will deflect 1/4" by hand, causing a vibration at 84mph.
If you're gonna find a junkyard axle, be sure to get 4.10's, you will be amazed the difference.
No, if you change gear ratio you WILL need a tuner to correct the speedo. When I went from 3:73 to 4.10's my speedo was off by 11mph at 75.
I went from 225 tire to 245 tires and at 6000ft elevation and my normal work gear it was a dog. I did 4.10's and a SCT x4 tuner with mikes 5 star tunes and wow what a noticeable difference! I drive a lot of interstate driving and the 4.10's are great for power. I can holeshot night and day difference, putting a lot of people to shame in a 6500lb work van with ladders on top!
If you're gonna find a junkyard axle, be sure to get 4.10's, you will be amazed the difference.
No, if you change gear ratio you WILL need a tuner to correct the speedo. When I went from 3:73 to 4.10's my speedo was off by 11mph at 75.
I went from 225 tire to 245 tires and at 6000ft elevation and my normal work gear it was a dog. I did 4.10's and a SCT x4 tuner with mikes 5 star tunes and wow what a noticeable difference! I drive a lot of interstate driving and the 4.10's are great for power. I can holeshot night and day difference, putting a lot of people to shame in a 6500lb work van with ladders on top!
I know the 4.10’s would increase torque and towing power, but if I’m changing gears then I’d want to go bigger.
I care less than before if the speedometer is incorrect because I’ve realized lately that I don’t use it. When my tires are newer the speedo reads lower than it should, and when tires are worn it reads higher than it should. I’ve been through 2 full sets of tires and I guess I’ve just gotten in the habit of watching the GPS instead of the dash.
Cargo Master
Joined: Jul 2003
Posts: 2,328
Likes: 14
From: Colorado
Yeah but getting a junkyard axle for $100 is a 2hr job to swap out rear ends vs having to regear yours now, save LOTS of $$$ and time. Last time I went two gear sizes lower change on a vehicle I was disappointed at how low it was and wished I just went one. You'd be surprised, the 4.10 in my van is perfect for me with 245's.
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Cargo Master
Joined: Apr 2013
Posts: 3,087
Likes: 24
From: Central Florida
Yeah but getting a junkyard axle for $100 is a 2hr job to swap out rear ends vs having to regear yours now, save LOTS of $$$ and time. Last time I went two gear sizes lower change on a vehicle I was disappointed at how low it was and wished I just went one. You'd be surprised, the 4.10 in my van is perfect for me with 245's.
I bet the difference between me and you is that my van will be used solely for towing a big trailer. I don’t care if I’m running 2,800rpm for an hour on the highway a couple times per month.
Currently I use it for daily commuting unloaded, so I’m not yet ready to jump in with 4.88’s. This should only be a few more months.
The cost you mentioned might be the deal breaker. As you mentioned, a new set of gears would be much more costly than a junk yard 4.10 swap.
Maybe I’ll do the cheap one now and the 4.88’s after the van officially retired from daily use.
what rpm are you running at 70mph?
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Cargo Master
Joined: Apr 2013
Posts: 3,087
Likes: 24
From: Central Florida
At exactly 2000 RPM on the highway I am running 64 mph. Do any of you folks have a way to calculate what my highway rpm would be with different gears?
I am getting ready to pull the trigger on this rear end replacement/repair. I am leaning towards buying a junkyard 4.10 and then keeping my old broken one to rebuild slowly but surely over the next few months. Probably with 4.56 or 4.88. Maybe 5.xx depending on the rpm calculation.
also, my current one has a limited slip, but I suspect many of the junkyard units will not. Is it hard to convert from open to limited slip? Or is it just a matter of adding in a few parts?
I am getting ready to pull the trigger on this rear end replacement/repair. I am leaning towards buying a junkyard 4.10 and then keeping my old broken one to rebuild slowly but surely over the next few months. Probably with 4.56 or 4.88. Maybe 5.xx depending on the rpm calculation.
also, my current one has a limited slip, but I suspect many of the junkyard units will not. Is it hard to convert from open to limited slip? Or is it just a matter of adding in a few parts?
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Cargo Master
Joined: Jul 2003
Posts: 2,328
Likes: 14
From: Colorado
4Lo.com :: Gear Ratio & Tire Size Chart
The vans have an ODD 32 spline axle that NO ONE makes anything for. Your only affordable hope is to get another OEM lame "trac loc" which is fair at best when you really need it and swap it in. I had heard that most only the powerstroke vans came with LSD. I haven't seen many.
The vans have an ODD 32 spline axle that NO ONE makes anything for. Your only affordable hope is to get another OEM lame "trac loc" which is fair at best when you really need it and swap it in. I had heard that most only the powerstroke vans came with LSD. I haven't seen many.
FTE Leadership Emeritus
Joined: Jul 2002
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From: Long Island USA
At any given speed, say 65MPH, at 2000RPM and you want to figure out what your RPM would be with a different gear ratio, do this:
RPM divided by old ratio, then multiply by new ratio = NEW RPM
SPEED multiplied by old ratio, divided by new ratio = NEW SPEED
So if you're running 2000 RPM at 65MPH, and you have 3.73's, and want to find out what RPMs you'll see with 4.10s, it's:
(2000/3.73)*4.10 = 2198.39 RPM
Likewise, speed at 2000RPM would be:
(65*3.73)/4.10 = 59.134 MPH
If you want to compute how much extra torque-to-the-ground you'll get with 4.10's versus 3.73s, divide 4.10 by 3.73 = 1.099 ... about 10% more torque-to-the-ground (1.099 is basically 110%).
10% is nothing to sneeze at, and you'd need to do a lot of engine mods to get that extra 10% torque - and you'd only get it at certain RPMs, not across the board like you would with a gear change.
It's one of the reasons when someone asks how they can get more towing power, I generally say gears. The one and only way to truly increase torque-to-the-ground across the board without any loss of power anywhere in the RPM range.
RPM divided by old ratio, then multiply by new ratio = NEW RPM
SPEED multiplied by old ratio, divided by new ratio = NEW SPEED
So if you're running 2000 RPM at 65MPH, and you have 3.73's, and want to find out what RPMs you'll see with 4.10s, it's:
(2000/3.73)*4.10 = 2198.39 RPM
Likewise, speed at 2000RPM would be:
(65*3.73)/4.10 = 59.134 MPH
If you want to compute how much extra torque-to-the-ground you'll get with 4.10's versus 3.73s, divide 4.10 by 3.73 = 1.099 ... about 10% more torque-to-the-ground (1.099 is basically 110%).
10% is nothing to sneeze at, and you'd need to do a lot of engine mods to get that extra 10% torque - and you'd only get it at certain RPMs, not across the board like you would with a gear change.
It's one of the reasons when someone asks how they can get more towing power, I generally say gears. The one and only way to truly increase torque-to-the-ground across the board without any loss of power anywhere in the RPM range.
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