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I have the same Comanche axle in my XJ. If you buy the Wrangler brake cables you will have plenty of legthe to run them out the back. It's alot easier than pulling apart the axle and swapping plates.
I think the lower hose has a lot to do with this problem. The factory has a spring inside to stop it from collapsing but parts stores ones don't. And this would help at higher RPM'S on the highway.
I noticed I have a front upper arm that is bent with a stress crack in it. I was thinking I could just cut it in the middle add some tube the length of the arm and weld it up. Anyone think this is a bad idea ?
I'm running 4.10's with the 5spd and 31's. I think it's a little low for the highway but great for everyting else. The motor is around 2,800 on the highway at 65 now.
You can get the Orings at Home Depot for 19 cents a each. I tore 2 factory ones and spent 40 bucks before trying these. I've put about a 1000. miles on mine with no leaks or problems.
You should pull the carpet entirely out of the jeep. I had the same problem with mine and all the pad and insulation was molded. I also had a good amount of rust starting on the floorpan. Gut the interior and sit inside while someone soaks the jeep and watch for leaks. mine was my side windows...
I didn't find a rodend in that size so I took mine to a machine shop. They drilled the bar out to 3/4 16tpi. It's a more common size in rodends I think.
I lraised the axle mount and I'm building a bar for the upper mounts. I figure with 5 to 6" a stock length would be good. Unless someone has a better idea.
I went to the you pull parts yard and got a trany and t-case out of a 91 XJ. I'm not sure if it's an AX-5 or AX-15. It has a 23 spline output shaft into the t-case but it also has a hydraulic realease bering like my old Peugeot.