Chrysler 8.25" Diff Rebuild in Duster...

[Pana BB Duster]

Had issues with the Dana / Chrysler 8.25" diff in the Duster. Purchased a Sure Grip Centre over a year ago and was given a later model Sure Grip which is slighty different...

Also purchased a set of 4.10:1 gears for the diff and all good to go to get put in but ran into a problem.
After a bit of research I did find out that there was a difference with Chrysler 8.25 housings from 60's to '76 and the '76 to '96 and then they went 29 spline as well..

First problem: Even with the carrier pushed all the way over there was still play in the gear and pinion backlash. Measure it with the existing 'open centre' carrier and there's a slight difference of about 7mm or so. What a pain in the ass... Diff Specialist is stumped as well as it all fits in perfectly..

Solution: Machine up a spacer to push the gear over...

Problem: Carrier has a centering groove so the spacer has to be grooved exactly to the centering groove as well..

Solution: Go and see the old man who's a 50 year veteran Fitter, Machinist, Toolmaker, Hydraulic's expert and everything else...

Outcome: Old Man Pana machined up a 7mm spacer which is unbelievable! The most accurate tolerances that I've seen. This will spin the diff specialist out as his solution was 'Go and Get a new Carrier'..

Another Problem: Due to the 7mm spacer, needed longer bolts as a lot of pressure going thru this part of the vehicle. No drama's, let's go and get some longer bolts..

And another problem: Range 40 places and I think it was going to be hard to purchase 10 x Left Hand Thread Bolts with Washer, 3/8 UNF, High Tensile. I was p#ssed!

Solution: Old Man Pana cracked it and said I'll mill them up on the CNC machine... So off goes Old Man Pana and mills up 12 x High Tensile, 3/8 UNF, Left Hand thread bolts with washer...

OLD MAN PANA has done it again. Check out a couple of the pics of the spacer and the bolts that he machined. Fricken sensational!

Sure Grip and gear went back to diff specialist today and the guys there spunout at the workmanship. Centre works a treat now and diff should be finished Monday and then back to Chris at SMS Performance to be finished off...





So if anyone want's some custom fabrication work done let me know.. I'm sure Old Man Pana will do mates rates...

[Muzzy 66]

Very handy..

[sms777]

Old Man Pana is an absolute legend! You are a lucky man Young Man Pana....

[Pana BB Duster]

Hey Chris, Tell me about it.. He's a fricken genius with stuff like that... Saved me a fricken headache and time in going and ordering a new LSD... :thanks:

[crossram 426]

is it in yet Pana? have you tested it's metal.........so to speak?