1963 Valiant - Rear differential Help please

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Tim.g.howard

Tim.g.howard

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First off .. car is a 225 /6, A904 automatic push buttons, manual brakes/steering, 13" wheels Small Bolt Pattern

I've bought fresh tires, rebuilt brakes and rebuilt the transmission and now rebuilding the '63 vintage 7 1/4 rear. My goal is to drive and enjoy the car as close to factory spec (per Service Manual) as possible/reasonable (so preservation?), and generally learn restoration with this car.

I had thought I'd collected all the parts to rebuild including pinion, carrier, axle bearings, shims, crush washer (though I don't think this was used in '63), 2.93 Ring and Pinion gears... and carrier gears from Rock Auto (Motive Gear listed under '63 Valiant).

I'd also had new springs made (ESSO Springs) to fit the smaller 7 1/4 housing. Oh, and new shocks of course.

I've removed, disassembled, and cleaned the housing, carrier, axles... and verified that the ring, pinion, and carrier gears all show excessive wear though there wasn't obvious metal material in the gear oil removed. (I can take and send photos if anyone cares to see).

Rear Diff Parts.jpg
Housing painted.jpg


So the problem is... when attempting to fit the new carrier gears into the '63 carrier... they don't fit by say 2-5 thousandths of an inch (a fact I've read about in this forum since).

Fitting carrier gears.jpg
Housing prepped.jpg


So what are my options? I'd like to keep the car "original"-ish... I'd like to keep my SBP 13" wheels and 9" Drum brakes. I'd like to not have to buy new spring mounts or rebuild the springs (though I believe it's just the U-Joints that are different?) I'd like to use this cleaned and freshly painted housing since I pulled a bunch of wire brush wires out of my hide prepping it.

Is it even possible to get a carrier that will fit newer gears or a rebuilt limited slip carrier that will fit this housing?


Thanks for any advice...
 
This is as designed. The carrier is an is an interference fit into the differential housing, because the carrier bearings are tapered roller bearings require some preload. I "think" the spec is like .006-.008" preload, but it's in the service manual. Now, about how to do that. The "correct" way is to use one of these. It's called a case spreader.
https://www.amazon.com/Mophorn-Differential-Housing-Spreader-Axles/dp/B07RFMBBSH?tag=fabo03-20
This is the correct way for all Dana differentials and although no one ever says it, the 7 1/4 IS a Dana. It's not a 27, 30, 35, 44, 60 or any of the other bigger ones, and I'm sure it has an assigned number, but I've never seen it referred to. But it is a Dana.
Notice the two "nubs". They fit into the holes on either side of the differential carrier housing. When you turn the turnbuckle, it tightens against the case and spreads it apart. But don't go too far. Usually no more than .020" is needed. Install your carrier, the races and shims and then loosen the spreader. But, I've been working on cars since 1974 and I've never used one. I always just get the carrier and shims at a little angle and gently tap them into place. Admittedly, I have broken a couple of the thick, cast iron shims through the years, because they are brittle, so if you do it that way, be gentle.
 
Thanks guys but I’m not talking about the carrier in the housing not fitting…. The carrier came out of this housing and it will go back in precisely as RustyRatRod describes.

The side and spider gears that I purchased from RockAuto for a 63 Valiant don’t fit INSIDE this carrier. Also the shaft upon which the spider gears rotate is secured with a roll pin in 63 not the set screw that comes with the replacement gears. Based on the wear of the carrier gears we removed, I’m fairly sure they were the culprit as to why the diff was locking up on me under load. So I’m really wanting to install a fresh set of gears. I’m just not hopeful I’ll find a fresh set of ‘63 vintage gears. I’m kind of hoping a newer vintage 7.25 carrier with fresh roller bearings will fit inside this housing (properly pre-loaded of course).

I sourced a fresh ring and pinion from someone on this forum and I’m fairly sure They’ll fit though not gotten to that step yet.

Make more sense?
 
I don't think the diff gears are available anymore in the aftermarket, I will look up the original part numbers for you tomorrow and you can check with a couple of parts dealers that have NOS stock and maybe they might have them.
 
Tim.g.howard said:
Thanks guys but I’m not talking about the carrier in the housing not fitting…. The carrier came out of this housing and it will go back in precisely as RustyRatRod describes.

The side and spider gears that I purchased from RockAuto for a 63 Valiant don’t fit INSIDE this carrier. Also the shaft upon which the spider gears rotate is secured with a roll pin in 63 not the set screw that comes with the replacement gears. Based on the wear of the carrier gears we removed, I’m fairly sure they were the culprit as to why the diff was locking up on me under load. So I’m really wanting to install a fresh set of gears. I’m just not hopeful I’ll find a fresh set of ‘63 vintage gears. I’m kind of hoping a newer vintage 7.25 carrier with fresh roller bearings will fit inside this housing (properly pre-loaded of course).

I sourced a fresh ring and pinion from someone on this forum and I’m fairly sure They’ll fit though not gotten to that step yet.

Make more sense?
Click to expand...
Well that explains it better, thanks. Send dat chit back. It's wrong and nobody offers the right stuff. EXCEPT for maybe AMS Obsolete Parts in Georgia, formerly Frank Mitchell Mopars.
AMS Obsolete Home Page
 
There were some changes that took place in mid 65 regarding the 7 1/4.
Chrysler refers to the gears as side gears and pinion gears.
Also the carrier is called a case in the parts catalog.
See 1965 parts catalog at mymopar.
Look at 3-06-5 side gear 2070023 fits 60 to mid 65
Side gear 2404194 fits mid 65 to 1976.
Scroll down to 3-07-1
Same with pinion gears.
Early gear 2070025
Late gear 2404195
Case also changed.
See 3-04-6
Early case 2070537
Late case 2404193
This is just from decades old memory but it seems like the newer 7 1/4 was slightly stronger than the earlier differential.
Rockauto listing maybe for the mid 65 and latter.

If you don't mind spending the money, the early gears to fit your carrier can be found on eBay or maybe a member can help.
Experts on the 7 1/4 please chime in.
 
Carrier, Case, Housing... "Case Spreader"... I wonder why anyone would ever get confused? :)

Thank you all for the help! And for the link to AMS Obsolete!
 
Ok here is a parts list and AMS shows all of it and Len Dawsons shows only the diff pinion gear.

2070024 washer for the side gears
2070023 side gear
2070025 pinion gear
2070026 washer for pinion gear
2070027 large pin for pinion gears
152229 pin that retains the large pin

AMS Obsolete www.amsnos.com phone number 706-337-4606 Fax 706-243-6368 Email [email protected]
Len Dawson's Deception Pass Motor Part's Anacortes Washington www.dpmotorparts.com

I have never purchased anything from AMS but back in the 80s pre internet days I did purchase a taillight lens from Len Dawson. Both these companies have been around a long time and both deal in NOS parts.
 
townsend said:
There were some changes that took place in mid 65 regarding the 7 1/4.
Chrysler refers to the gears as side gears and pinion gears.
Also the carrier is called a case in the parts catalog.
See 1965 parts catalog at mymopar.
Look at 3-06-5 side gear 2070023 fits 60 to mid 65
Side gear 2404194 fits mid 65 to 1976.
Scroll down to 3-07-1
Same with pinion gears.
Early gear 2070025
Late gear 2404195
Case also changed.
See 3-04-6
Early case 2070537
Late case 2404193
This is just from decades old memory but it seems like the newer 7 1/4 was slightly stronger than the earlier differential.
Rockauto listing maybe for the mid 65 and latter.

If you don't mind spending the money, the early gears to fit your carrier can be found on eBay or maybe a member can help.
Experts on the 7 1/4 please chime in.
Click to expand...
I have wondered that myself. the 63-axle housing P/N is 2404074 what was it in the later catalog?
 
They just recently sold a friend a 7 1/4 sure grip rebuild kit that I installed for him, so they likely have what you're looking for.
 
IMG_2794.jpeg


Got to show some love for the “Best All Around Compact Anyone Has Come Up With Yet”…. As designed…
 
I called AMS and have those part numbers ordered for a total of $270.

2070024 washer for the side gears
2070023 side gear
2070025 pinion gear
2070026 washer for pinion gear
2070027 large pin for pinion gears
152229 pin that retains the large pin

WAY cheaper than building a time machine!

I'll post a follow up and let you all know when I get the diff assembled...


Thank you all!
 
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