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D27 Powerlock Install

Discussion in 'Builds and Fabricators Forum' started by FinoCJ, Nov 29, 2022.

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  1. Nov 29, 2022
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    Just beginning to think about a powerlock install for the D27 in the cj5...used unit that I am working on disassembly and cleaning. It was already partially disassembled when I got it, so not 100% sure I got everything I need. Does it look complete to you all? I have both halves of the case, two side gears, the 4-gear and cross shaft, some sort of central hub that the side gears and clutch pack sit in, and 5piece clutch pack (3 with tabs).
    [​IMG]

    Also, the 2 of the clutch pack pieces have some significant grooves/wear - so assume those will need to be replaced. Need to find a supplier for those.
    [​IMG]

    I don't really know how these things go back together - not sure how the 4gear and cross-shaft sit inside the case - but basically after cleaning and new clutch pack discs, I should be able to assemble the thing together on the bench. I recognize I will need some sort of axle shaft to ensure the splines all line up while bolting the two halves of the case together. But if I can at least get the unit rebuilt and ready for install, then when I get to pulling the axle out of the jeep, I can focus more on swapping out the cases....it'll be more like when I installed the eaton e-locker case in the rear - I will be swapping the ring gear over to the new case, and start test fitting using the shim set-up that came out, then modify to fit.

    So in addition to finding to the clutch packs, I also need to order a D27 differential rebuild kit for the pinon and carrier bearings, shims etc, and some D27 set-up bearings would be nice as well.

    If anyone has good technical info on rebuilding the case - be happy to take it.
     
    FinoCJ, Nov 29, 2022
    #1
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  2. Nov 29, 2022
    Stakebed

    Stakebed Member

    Lake Co....
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    Doesn't Herm service these?
     
    Stakebed, Nov 29, 2022
    #2
  3. Nov 29, 2022
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    If your picture shows everything you have you are short clutches, which a kit should have them all, and missing one clutch ring. That’s the dished shaped piece with splines. The side gears sit in those and the clutches put pressure on the flat side. 25,27, and 30’s use the same clutch pack. I have a new set if interested I was going to put up for sale.
    There should be the same number of clutches on each side so you need an even number. I “think” the FSM has info on servicing these. I’ll look this afternoon and see what info I have on hand. I’ll dig out the clutch pack I have also.

    Richard at R&P usually has some misc. parts around for those. I’m having lunch with him tomorrow so will try and remember to ask.
     
    nickmil, Nov 29, 2022
    #3
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  4. Nov 29, 2022
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    just figuring this out as well....Its possible the clutch hub/ring and disks are still inside one of the case halves....its all soaking in cleaner at the moment so hoping its in there and will fall out. Otherwise, I'll need to find a clutch ring....I would probably take your clutch disk pack. Later today I should be able to confirm what pieces I have and what I need.
     
    FinoCJ, Nov 29, 2022
    #4
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  5. Nov 29, 2022
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    Also, the cross-shaft in this case has the 'hole' with the pin (maybe spacer block) that I think was used for rear axle set-ups? Is it any issue for a front axle set-up? Will I leave the hole open or is it okay to leave the pin in it?
     
    Last edited: Nov 29, 2022
    FinoCJ, Nov 29, 2022
    #5
  6. Nov 29, 2022
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    That is basically a thrust block for a tapered rear axle. If used in the front it needs to be removed or you won’t be able to get your axle shafts all the way in. It doesn’t hurt a thing to not have it there in a front application. Typically the button halves are held together with a simple roll pin. That probably came out of the rear of a Scout 80 with a tapered axle 27.

    If you have a neats foot, or rolling head prybar, you should be able to gently pry the clutches out of the case halves.
     
    nickmil, Nov 29, 2022
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  7. Nov 29, 2022
    dnb71R2

    dnb71R2 SuperDave 2023 Sponsor

    Grand Mesa, CO
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    PM sent with bulletin attached.
     
    Last edited: Nov 29, 2022
    dnb71R2, Nov 29, 2022
    #7
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  8. Nov 29, 2022
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    2903F5B2-931E-4E67-937E-C65A4F01FD82.jpeg ECE0F837-3CDF-43F7-9631-95EDF137A38E.jpeg Not very good pictures but these are from my 8-71 printed FSM in the rear axle section.
     
    nickmil, Nov 29, 2022
    #8
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  9. Nov 29, 2022
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    Found all the pieces....a couple of these clutch disks are also grooved....some new clutches and I think it should all work fine....now I just need a dummy axle shaft (or have to pull one out of the cj).
    [​IMG]
     
    FinoCJ, Nov 29, 2022
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  10. Nov 29, 2022
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    Looks like you have everything. Make sure you clean out the threaded holes very thoroughly and use threadlocker upon final assembly. I sent you a message.
     

    Attached Files:

    nickmil, Nov 29, 2022
    #10
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  11. Nov 30, 2022
    Renegade ll

    Renegade ll Member

    Thayne Wyoming
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    James I don't know if you need it but I have the part numbers for the pinion inner and outer bearings and races and the carrier bearings and races you will need.
     
    Renegade ll, Nov 30, 2022
    #11
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  12. Nov 30, 2022
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    If they are easy to get, you are welcome to post them up....I assume the bearnings are all the the same for the PL and for the OEM open case. I will probably go the 'installation' kit route - something like this:
    https://www.summitracing.com/parts/yga-14014
    Yukon comes with Timken bearings, and I'll need shims and seals etc, but bit pricey I thought. Richmond gear didn't have a set for the D27 that I could find - so might have to search for the Yukon kit on sale somewhere.
     
    FinoCJ, Nov 30, 2022
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  13. Nov 30, 2022
    Renegade ll

    Renegade ll Member

    Thayne Wyoming
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    James here is what I put in mine.

    Dana 27 AF Timken bearings and races.


    Pinnion bearings inner= HM 88649 outer= 02872
    Races inner= HM 88610 outer= 02820

    Carrier Bearings LM 501349
    Race LM 501311

    Pinnion Seal Walcks #639265

    Pinnion Shim kit Walcks # 649228
    Carrier Shim Kit Walcks # 648061


    Dave aka Wheelie can you add this in for part numbers from your earlier post with Dana 27 PN #'s
     
    Renegade ll, Nov 30, 2022
    #13
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  14. Nov 30, 2022
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

    York, PA
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    There is some info in this old thread of mine. I'll find my notes and try to confirm the bearing numbers. I thought my thread was more complete than this but I may be thinking of the PMs with Nick when I was having trouble with reassembly. I'll keep searching but for now.....


    http://www.earlycj5.net/xf_cj5/index.php?threads/118208/page-3


    And here is the other thread when I was having trouble with the assembly and install of axle shafts

    http://www.earlycj5.net/xf_cj5/index.php?threads/122127/
     
    Last edited: Nov 30, 2022
    wheelie, Nov 30, 2022
    #14
  15. Nov 30, 2022
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    Thanks Dave....you have a couple threads on this I've found as well as an old thread from jzeber from like 2006. I was kind of worried about this at first, but after seeing it in person and getting help from Nick, the PL shouldn't be too difficult following the FSM for disk arrangement. Once I get the case built, then it's just like doing the e-locker install - which is the hard part, but hopefully not as intimidating the second time around.
     
    FinoCJ, Nov 30, 2022
    #15
  16. Nov 30, 2022
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

    York, PA
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    I think I got a clutch kit from herm. Maybe. Not sure. but I think he was the only game in town for a complete kit at the time. I still mine is too tight. Not sure if I did something wrong during assembly or if it needs to wear in some more or the clutches aren't the same as originals. I dunno. Hopefully yours works as you want it to. I think Michael and I had about the same experience with our power locks while with you in 2021. I'd like to think that I put the discs in properly but maybe I didn't. I don't know. I'm sure you'll have better luck.


    edit: days later.......found my build notes from my 27 but no note on pinion bearing numbers. Sorry.
     
    Last edited: Dec 7, 2022
    wheelie, Nov 30, 2022
    #16
  17. Dec 10, 2022
    Renegade ll

    Renegade ll Member

    Thayne Wyoming
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    This is the post I was thinking could add some part numbers to.

    http://www.earlycj5.com/xf_cj5/index.php?threads/121241/
     
    Renegade ll, Dec 10, 2022
    #17
  18. Dec 10, 2022
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
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    Make sure part # 3 are not cupped out to bad. If they are, have a machine "lightly" dress them up. I have a NOS PL for a 19 spline D27 if need be.
     
    Jeepsterjim, Dec 10, 2022
    #18
  19. Dec 10, 2022
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    If you can find a couple thin clutch discs you can replace thick ones with thin ones to tune how it works. Fortunately I had a couple extras so sent them to him with the clutch kit and alignment tools. If you look close at the tools in the picture I posted, one of the tools has a nut welded to it. That’s so you can check the breakaway torque (point at which it starts to slip) with a torque wrench. I’m pretty sure the FSM has this information. The alignment tools are just cut off and modified inner 25/27 axle shafts.
    Yup, Herm is having the clutches made offshore
     
    nickmil, Dec 10, 2022
    #19
  20. Dec 10, 2022
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
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    Some of the guys are lightly media blasting the clutches and adding a extra one if need be. IMHO, NOS Spicer clutch packs are best.
     
    Jeepsterjim, Dec 10, 2022
    #20
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