Power Lock LSD questions

Looking for some info on power lock LSD units. I am looking to buy them for the front and rear of my stock 63 CJ5. Is there anything I should beware when shopping for them? I was reading that the earlier power locks used a slighlty different set-up than the later ones. Are parts readily availiable for the units (early and later styles)? What do you think I should pay a piece for them? What should I look for when considering a unit? How would you gauge the difficulty and expense to rebuild one of these units?
Thanks.

 

Be aware that there are 2 different ones for lower or higher gear ratios. Series 3 for 3.73 and, numerically lower ratios. Series 4 for 3.92 and numerically higher ratios. Price depends on condition. If I'm buying a used part, I consider it in need of service unless there is paperwork, receipts, to prove otherwise. A ball park figure for a used Power lock, in my opinion, is around 150 bucks. Of course, less is always good.

 

I bought a used unit off ebay for my D27. Pretty easy to take apart and service. As I recall the parts are readily available. I was told to make sure you put it back together the same way it came apart, meaning the plates and discs need to be kept in order.
Good write up here: http://www.binderplanet.com/forums/showwiki.php?title=Power+Lock+Clutch+Replacement

 

The clutches are available as the 25/27/30 Powerlocks use the same clutches. The gears, shafts, etc. are not available new afaik. Hermtheoverdriveguy may be having Chinese copies made but otherwise not available.


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Good info, thanks Nick!

 

And the clutch packs for the Dana 44? Any particular vendors?

Another question: if one wanted to turn a 19 spline p'lock into a 30 spline, could you do it by replacing side gears, cross shafts, etc?

 

Yes and no.
The cross shafts are identicle.
You can put 30 spline side gears and side gear rings into a 19 spline Powr Lok Case but it still will not be a true 30 spline Powr Lok.
That's because the true 30 spline case has slightly thicker and larger diameter journals.
The 30 spline case requires different cone rollers than a 19 spline case yet the differential case bearing cups are identicle.

 

Jeez oldtime, the suspense is killing me here!

Got a part number for that cone?

 

The cone roller bearing is the same for a 30 spline Powerlock and 30 spline open case and the 19 spline Powerlock shares the same cone roller bearing as a 19 and/or 10 spline open case.


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I suggest that you should forget about installing a 30 spline Powr Lok if this unit is intended for use with a 2 piece full floating axle shaft conversion and or a Hurricane engine.
The Hurricane engine will not be able to break 19 involute spline shafts unless severly abused.

Yes it's true that the 30 spline axles are larger diameter and thereby they are stronger.
But the 2 piece full float conversions will always negate the extra shaft diameter anyway.
All 2 piece full float axle shaft conversions reduce the shaft diameter to the same dimension at the drive flanges.

The only valid reasons to go with 30 spline side gears is if you have v6 or greater power, super low transmission and transfer case ratios or your installing flanged type axle shafts.

19 spline series 4 Dana model 44 Power Loks are certainly the most common of all the various Powr Loks and the 30 Spline D44 Powr Loks are few and far between.
The rare Powr Loks certainly demand a greater investment.

Here's my complete CJ bearing chart: http://www.film.queensu.ca/cj3b/Tech/Bearings.html

 

Thanks Ken and Nick.

If I do the full floater, I'll go with Dutchman axles- flanged, one piece.

I know the 30 spline requires milling the spindles- 19 spline the same thing?

Was down at the picknpull place a few days ago and picked up some 11" brakes- all 4 with front hubs and spindles for 65 bucks off a 79 postal (measured the drums and they don't look like they have been turned yet). Had to pull the axles to get the rear backing plates and was impressed with the beefiness of the axle shafts. I went back the next day and got the rest of the rear end as the bearings and splines were in exceptional shape. It was a lot better than the beat up axle my DJ has in it now. Anyhow, I see now why the flanged 44 is held in such high regard.

 

Yeah 30 spline 1 piece Duchman axle shafts should be considered as absolute top of the line concerning overall shaft strength and durability.
If you go that route I would then recommend 30 spline Powr Loks.
Realize that Jeep never used 30 spline Powr Loks.
So search for D44 Powr Loks from GM pickups. (1960's)
Also search for D44 Powr Loks from IH (1960's and 1970's)

Yes you will need to rework the spindle flange index circle.