2006 Dyna IPB failure notes & cause
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Big Kahuna HDF Member
Joined: Feb 2006
Posts: 23,881
Likes: 34
From: USA
2006 Dyna IPB failure notes & cause
Sent some pics of a failed (6-7000 mile) 2006 dyna inner primary bearing to a bearing analyst I know who is a graduate mechanical engineer with 30+ years experience in bearing design/analysis. Here is what he said:
The photo's are not that clear, but looks like a contact stress failure to me. Normally, the highest contact stress occurs on the inner ring component and the inner ring should be the primary failure mode due to a fatigue type failure. What do the rollers look like? Are there any fatigue areas on any of the rollers? The premature failure life indicates something was wrong.
The bearing could be set up with the incorrect mounted clearance. This type of bearing is very unforgiving for shaft misalignment, and shaft misalignment will spike the contact stress to a level to cause premature failure. I would email your information direct to Harley Davidson Engineering for their input.
They should want to perform a bearing failure analysis on this part. If there is a misalignment problem caused by manufacturing errors between the engine and transmission, the bearing failures will repeat upon replacement. I suspect bearing misalignment to be the root cause causing excessive contact stress on the inner ring which causes the bearing to be overloaded.
The amount of damage on the inner race indicates the bearing started to fail immediately, and the inner race spalling progressed to a point at 6000 miles that the bearing damage is audible by bearing noise.
SO there you have it folks....the 2006 dyna IPB's fail due to shaft misalignment.
The photo's are not that clear, but looks like a contact stress failure to me. Normally, the highest contact stress occurs on the inner ring component and the inner ring should be the primary failure mode due to a fatigue type failure. What do the rollers look like? Are there any fatigue areas on any of the rollers? The premature failure life indicates something was wrong.
The bearing could be set up with the incorrect mounted clearance. This type of bearing is very unforgiving for shaft misalignment, and shaft misalignment will spike the contact stress to a level to cause premature failure. I would email your information direct to Harley Davidson Engineering for their input.
They should want to perform a bearing failure analysis on this part. If there is a misalignment problem caused by manufacturing errors between the engine and transmission, the bearing failures will repeat upon replacement. I suspect bearing misalignment to be the root cause causing excessive contact stress on the inner ring which causes the bearing to be overloaded.
The amount of damage on the inner race indicates the bearing started to fail immediately, and the inner race spalling progressed to a point at 6000 miles that the bearing damage is audible by bearing noise.
SO there you have it folks....the 2006 dyna IPB's fail due to shaft misalignment.
IPB Failure
It would also tend to explain why one guys gets 6k out of the bearing and the next 40k. You would think that the Moco would design the case so that the assembler could not put the shaft into the bearing with any significant misalignment. Sounds like the way it is done makes the life of your IPB dependent upon how much of a hurry the assembler is in or how much he tied one on the night before.
Thread Starter
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Big Kahuna HDF Member
Joined: Feb 2006
Posts: 23,881
Likes: 34
From: USA
There are 2 other theories out there that I am checking on:
1. The assembler covered the oil galley that feeds the bearing with the wrong snap retaining ring orientation and starved the bearing of lubricant
2. The bearing assembly was not heat treated (hardened) deep enough at the supplier.
I'll add the responses when I get them.
1. The assembler covered the oil galley that feeds the bearing with the wrong snap retaining ring orientation and starved the bearing of lubricant
2. The bearing assembly was not heat treated (hardened) deep enough at the supplier.
I'll add the responses when I get them.
Supporter
Joined: Jan 2007
Posts: 15,788
Likes: 5,625
From: along the shore of Mishigami
The H-D primary chain auto adjuster came out in 06, from what I can tell when this adjuster tightens it's locked in that adjustment. An aftermarket auto adjuster allows the tighten chain to "float" on two springs that still maintain proper adjust or it uses primary oil as this "hydraulic" adjust. Now what I know is this when two shafts are on one chain and this chain overtightens, the shafts are actually pulled together. One can't see this but the shafts are coming out of alignment, wearing against the races or bearings. My 2 cents.
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Road Master
Joined: Aug 2006
Posts: 837
Likes: 1
From: Radcliff, Ky
Well when they were going out they only lasted about 7K miles. Mine went out about 7700, at 5 k there was a metaillic ball on my drain plug in the primary, (amsoil). now i have 20500 and it has not shown any more where whatso ever.. They had some junk bearings... along with some under enginerring.. all good now..
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Extreme HDF Member
Joined: Sep 2006
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Harley fugged up on that bearing and they knew it when they started the "free replacements" every 15k miles. IMO, it was dirty pool to send out a letter later rescinding that service.
Here's a copy of each letter for those of you that are going WTF is he talking about:
Here's a copy of each letter for those of you that are going WTF is he talking about:
Last edited by xxxflhrci; Dec 3, 2008 at 08:50 PM.
what an AWESOME POST!!! thanks man! i jsut saved that... somewhere downt he line with HD this willbe a huge issue... 
want to make sure i know what i am talking about hahahaha thanks again brother GREAT POST!
want to make sure i know what i am talking about hahahaha thanks again brother GREAT POST!