New Revolution Shafts Seem Too Long?

LJGreg · Sep 3, 2024

I'm rebuilding a Dana 30 HP out of a 1997 XJ. I have installed a ARB RD103 locker (30 spline) and am using Revolution shafts (DC-Dana 30-TJ-30). I'm using Blaine's knuckles from the Super 16" BBK and re-using my Timken unit bearings (HA597449).

Passenger side shafts went in just fine - they had some back and forth play before tightening up the axle nut. My issue is the driver side shaft are about 1/16" too long. It is bottoming out in the locker leaving a gap between the unit bearing and the knuckle. I've tried a few light taps but it's definitely bottomed out. Any ideas?

GregBelleville · Sep 3, 2024

Looks like your part number from Revolution is for a TJ Dana 30, did you confirm this same part number also applies to an HP Dana 30 from an XJ?

jjvw · Sep 3, 2024

Put the dust cover back on

hosejockey61 · Sep 3, 2024

Depending on what your locker shim stack needed to be, it could have moved your locker closer to the driver side.

CMBD · Sep 3, 2024

Is the end of the shaft hitting the pin in the diff?

If it is you can trim the end of the shaft to get the length you need.

But, I would not give the advise of just skipping to that part before you look in to exactly what is causing the issue.

SRCustom · Sep 3, 2024

If you've gone through it all again, and you're sure you've done it right...

NskLJ · Sep 4, 2024

LJGreg said:
I'm rebuilding a Dana 30 HP out of a 1997 XJ. I have installed a ARB RD103 locker (30 spline) and am using Revolution shafts (DC-Dana 30-TJ-30). I'm using Blaine's knuckles from the Super 16" BBK and re-using my Timken unit bearings (HA597449).

Passenger side shafts went in just fine - they had some back and forth play before tightening up the axle nut. My issue is the driver side shaft are about 1/16" too long. It is bottoming out in the locker leaving a gap between the unit bearing and the knuckle. I've tried a few light taps but it's definitely bottomed out. Any ideas?

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Where is your brake dust shield/ backing plate?

mrblaine · Sep 4, 2024

LJGreg said:
I'm rebuilding a Dana 30 HP out of a 1997 XJ. I have installed a ARB RD103 locker (30 spline) and am using Revolution shafts (DC-Dana 30-TJ-30). I'm using Blaine's knuckles from the Super 16" BBK and re-using my Timken unit bearings (HA597449).

Passenger side shafts went in just fine - they had some back and forth play before tightening up the axle nut. My issue is the driver side shaft are about 1/16" too long. It is bottoming out in the locker leaving a gap between the unit bearing and the knuckle. I've tried a few light taps but it's definitely bottomed out. Any ideas?

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Put the dust shield back on, that buys you .035 and then cut 1/16" off of the end of the shaft and deburr. We do it all the time although it is generally the other side. But, before you get carried away, check the ramp up on the seal surface on the inboard side. I've dealt with a couple where that ramp was hitting the end of the locker and it was not the shaft being too long.

LJGreg · Sep 4, 2024

Thanks guys, I totally forgot about the dust shield but even with it, it is still tighter than I would want. I'll check the seal and cut as needed.

LJGreg · Sep 4, 2024

Success. As Blaine mentioned, I confirmed it wasn't the ramp up section that was making contact so just used the bandsaw to cut 1/16" off. To RGA's credit, I heard back from them and they confirmed I could either cut it ("would not affect strength or warranty") or they could ship me a new one.

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New Revolution Shafts Seem Too Long?

LJGreg

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GregBelleville

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jjvw

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hosejockey61

FAFO

CMBD

Button pusher.

SRCustom

Disillusioned JL Owner

NskLJ

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mrblaine

Crew Member

LJGreg

TJ Enthusiast

LJGreg

TJ Enthusiast

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