Gear break-in: cooling differential

[UKTJ]

Apologies if this info is here somewhere, but a search has not pointed me to it.

After trying to do my own regear I had issues and lost confidence, so have had a garage do it for me. Places that will work on 20 year old Jeeps are few and far between in the UK, so when I pick it up tomorrow I will have a 250 mile drive home.

The Revolution Gear break in process requires a number of short drives at low speed, with the need to let the differential cool in between. I will need to do this as part of my drive home. However, I have been unable to find any info on how long I need to let the differential cool for. I understand this may depend on a number of factors, so my plan is to go no faster than 35mph for the first few 20 mile stints and to allow time to cool between. Forecast says temperature will be about 60 degs in the UK tomorrow. Any rough indication of how long I need to stop to allow the differential to cool would be much appreciated.

 

[KennethS]

I found this information for gear break-in:

https://www.randysworldwide.com/web_images/pages/Install Manuals/YukonKitInstallManual_Complete.pdf

 

[Rut Row]

I put in Revolution gears last year and had the same issue. I talked and emailed with them several times and they said let the diff cool until you can touch it.

 

[flyinfish]

Here's the Revolution Gear break-in instructions:

 

[SRCustom]

I've bought new vehicles and have not had to endure this level of break-in... Why is this process necessary for replacement gear sets, and not factory new axles? Are the replacement gears made from a lesser grade steel?

 

[flyinfish]

A new vehicle's ring and pinion doesn't have to be broke-in like an aftermarket set because they are most of the way there from the factory with exception of the final work hardening that comes from actual driving miles. New vehicles have break-in periods mainly for the engine but during that 500 miles the ring and pinion finish their work hardening under lighter conditions than normal driving.

 

[UKTJ]

Here's the Revolution Gear break-in instructions:

View attachment 606802

Interesting, that is slightly different to the instructionsnthey have on their website.

How to Break in a Ring and Pinion
The suggested break-in procedure for a ring and pinion gear is as follows:

• - Drive 15 to 20 miles under normal driving conditions (no highway speeds), stop and let differential cool before proceeding, repeat this process 2-3 times
• - Avoid heavy accelerating during the break in process
• - Keep the vehicle under 60 MPH for the first 100 miles
• - Highway driving also requires proper break-in due to the higher heat temperatures produced, drive 15-20 minutes at max 65MPH, stop and let differential cool before proceeding, repeat this process 2-3 times
• - Driving on a new ring and pinion before the initial 500 mile oil change should be under normal driving conditions: no hard starts, racing, off-roading, towing, and should not be flat towed.
• - Change Gear Oil after the 500 mile break-in, this removes metal particles and phosphate coating from the gear set during the break-in period.
• - *Towing: After the 500 mile oil change, the first towing should be less than 15 miles, then let the differential cool before proceeding, Repeat this process 2-3 times

https://revolutiongear.com/blog/rin...fzF4S2KQ8mKY6uVVB1iZ0ilX8Yu9MSlrj4Zaoq4Dljuwh

 

[flyinfish]

Interesting, that is slightly different to the instructionsnthey have on their website.

How to Break in a Ring and Pinion
The suggested break-in procedure for a ring and pinion gear is as follows:

• - Drive 15 to 20 miles under normal driving conditions (no highway speeds), stop and let differential cool before proceeding, repeat this process 2-3 times
• - Avoid heavy accelerating during the break in process
• - Keep the vehicle under 60 MPH for the first 100 miles
• - Highway driving also requires proper break-in due to the higher heat temperatures produced, drive 15-20 minutes at max 65MPH, stop and let differential cool before proceeding, repeat this process 2-3 times
• - Driving on a new ring and pinion before the initial 500 mile oil change should be under normal driving conditions: no hard starts, racing, off-roading, towing, and should not be flat towed.
• - Change Gear Oil after the 500 mile break-in, this removes metal particles and phosphate coating from the gear set during the break-in period.
• - *Towing: After the 500 mile oil change, the first towing should be less than 15 miles, then let the differential cool before proceeding, Repeat this process 2-3 times

https://revolutiongear.com/blog/rin...fzF4S2KQ8mKY6uVVB1iZ0ilX8Yu9MSlrj4Zaoq4Dljuwh

The image I posted was from the sheet inside a set of Revolution 5.38's I installed in late 2019 so probably the reason for the slight variation.

 

[jjvw]

Apologies if this info is here somewhere, but a search has not pointed me to it.

After trying to do my own regear I had issues and lost confidence, so have had a garage do it for me. Places that will work on 20 year old Jeeps are few and far between in the UK, so when I pick it up tomorrow I will have a 250 mile drive home.

The Revolution Gear break in process requires a number of short drives at low speed, with the need to let the differential cool in between. I will need to do this as part of my drive home. However, I have been unable to find any info on how long I need to let the differential cool for. I understand this may depend on a number of factors, so my plan is to go no faster than 35mph for the first few 20 mile stints and to allow time to cool between. Forecast says temperature will be about 60 degs in the UK tomorrow. Any rough indication of how long I need to stop to allow the differential to cool would be much appreciated.

Does your gear installer have a warranty for the work? What does your gear installer suggest for the break in process?

 

[BC Moto]

Last re-gear wasn't on the jeep but in my truck and I go the polished seat from revolution gears, New install drove it 20min let it cool and then drove it 400miles home and it was fine, just change the fluid. My friend got a re-gear done and we went wheeling the next day. The newer revolution gears are alot better

 

[Ashim]

You would be much better off finding someone that could trailer your Jeep back home. Otherwise be prepared for a long trip home. Do a couple of slow 20 minute drives and touch the differential cover with your hand to determine if it has cooled sufficiently. I would gradually increase speed and time between the cooling stops. Plan a lunch stop and dinner stop along the way.

 

[jjvw]

You would be much better off finding someone that could trailer your Jeep back home. Otherwise be prepared for a long trip home. Do a couple of slow 20 minute drives and touch the differential cover with your hand to determine if it has cooled sufficiently. I would gradually increase speed and time between the cooling stops. Plan a lunch stop and dinner stop along the way.

What if his gear installer has a different suggestion?

 

[Ashim]

Then definitely follow the installer's instructions if he is providing a warranty.

 

[UKTJ]

Does your gear installer have a warranty for the work? What does your gear installer suggest for the break in process?

No warranty, not surprising as I supplied the parts. Suggestion is to follow manufacturer's instructions, again, no big surprise there.

 

[UKTJ]

You would be much better off finding someone that could trailer your Jeep back home. Otherwise be prepared for a long trip home. Do a couple of slow 20 minute drives and touch the differential cover with your hand to determine if it has cooled sufficiently. I would gradually increase speed and time between the cooling stops. Plan a lunch stop and dinner stop along the way.

It's a four hour drive to get there on the motorwat, leaving early and hoping to arrive by 10,30am. Anticipating maybe 12 to 14 hours to get back on back roads, including many stops and slow speeds.

 

[KennethS]

Sight-seeing road trip!

 

[lBasket]

I've bought new vehicles and have not had to endure this level of break-in... Why is this process necessary for replacement gear sets, and not factory new axles? Are the replacement gears made from a lesser grade steel?

I don't know the answer for this specifically but I think RGA sells R&Ps that don't need a breakin (for more $$$)

 

[macleanflood]

Sight-seeing road trip!

Yeah, plan your route via pubs...

-Mac

 

[lBasket]

Sight-seeing road trip!

I definitely used my "forced mileage" I had to pay gas for to go see some cool stuff lol. Might as well

 

[tworley]

My last regear in 2020 I drove for about 20 min then let the gears cool for about another 20 min, then hit interstate at 75 mph for the hour drive home.