Axle Dilemma - Looking For Opinions

[Jawa]

:exclamati Long Post Alert! :exclamati

After lifting and going to 33s this summer I've had a sort of harmonic vibration that's really bad around 45-55 mph. I was just dealing with, pulling one of those "I really need to fix that some day" sort of things, until a week or so ago when I noticed I'd developed a nasty pinion leak in the front. I finally pulled the front shaft yesterday and it seems to have eliminated most of the vibration.

I'll rebuild the front shaft, but my dilemma is what to do with the axle. The D30 I currently have will need new pinion bearings and seals and also needs at least one new hub assembly. Plus I've got to pay someone to install the pinion bearings/seals and set up the gears. I figure at least $225. That's assuming pinion bearings and seals for about $50, a cheapy hub assembly for $75 and finding someone willing to help me do the install work for $100. Who knows what I'll find when I crack open that diff - 5 months of vibes might have caused other damage as well.

As some of you know, I've got a pair of waggy D44s waiting to go under my rig. Both will need fabrication work and new gears before they can go under the rig. They've got a different bolt pattern, so a new set of wheels is needed as well. I'm figuring the whole shebang will cost me in the neighborhood of $1750.

Thats made up of... $550 for gears, overhaul kits, and a 4 series carrier (both axles need a new carrier, but I've already got one on hand). I was looking at the TNT truss with all the mounts, which is another $550. Add in $350 for a set of wheels. That leaves me with $300 or so to pay people for welding and gear setup work - not much at all. That doesn't even include the cost of mounting and balancing tires on the new wheels, possibly needing to modify the driveshafts, painting the axles, etc.

So.... the question is: Do I bother spending $225+ on the D30 when I plan on getting rid of it next year or am I better off just coughing up the $1750+ now and swapping in the D44s? Does anybody have some suggestions to cut the cost of the swap? Is it even reasonable for me to think that someone would help me replace bearings and set up gears for about $100 per axle?

Sorry for the loooooong post!

 

[YELLAHEEP]

I have another option for ya...........

PM sent.

 

[Hypoid]

Double crap!!! Axles are the weekend special again. This is also the last weekend special EVER.

I could have pulled one for you yesterday, today is out of the question.

Does the pinion yoke move side to side? You may have dodged a bullet and only need a seal.

This guy here has been recommended often: http://www.naxja.org/forum/member.php?u=11536

I have corresponded with him about my projects and found the prices very reasonable.

 

[Jawa]

Thanks for the PM Yella, I'll definitely keep that option on the table.

Question: if it's just the seal that's bad, can that be replaced without pulling the pinion?

 

[yetimotronic]

the seal can be replaced without pulling the pinion. u may have the crush sleeve or the shims for the pinion preload which have to be removed/replaced properly/precisely when doing this work. i did not read a year for your axle so i'm not sure which you have.

 

[YELLAHEEP]

Pinion seals on our XJ's can always be replaced without worrying about the pinion settings - just don't get carried away tightening the pinion nut after replacing it and you'll be fine. I've done it many times.

But, if you got any slop at all in the pinion shaft, be it side to side or in/out then you've got a more serious problem than just the seal. And yeah, that's gonna require a new crush sleeve at the very least - which I understand are hard to get by themselves (generally part of a master install kit only).

 

[Jawa]

Okay, so I've checked the pinion and I can't detect any play either side to side or in and out. I haven't put any research into replacing a pinion seal. I assume the only part I'd need is the outer pinion seal and that to replace it I'd remove the pinion nut and... what? just pull it apart and replace the seal? What's involved?

Thanks for the input guys. If I can just replace the pinion seal and the bad hub assembly, I'll go ahead and do that for now.

 

[YELLAHEEP]

Yup, remove the pinion nut, pull the pinion yoke off, use tool to pry off the seal (generally a good stout screwdriver and leverage) then position the new seal and lightly tap the edges gradually all around to seat it. If you have a large enough socket that'll sit on the edges of the seal and deep enough to go over the pinion shaft without touching it, that's the best way to seat the new seal. (IIRC, the 36mm socket used to remove the hub nut on the front axles works pretty good.... :dunno

 

[Jawa]

Excellent! Now I just need to find some time and another day where the weather is cooperative.

I haven't driven the heep much since pulling the front shaft, but it seems like I still have slight harmonic vibes around 45-55. Could that be a potential transfer case problem? Maybe just the rear shaft? I've read tons of vibe threads on here and everyone seems to go back to driveline angles and driveshaft u-joints, but I'm certain my angles are fine and the u-joints have only 5k miles on 'em...

The vibes are much more pronounced under acceleration. When I let off the gas they go away almost entirely. Thoughts?

 

[YELLAHEEP]

Turn up your stereo and create "better" vibes...... the bad ones will go away.

 

[Jawa]

I wish! My stereo isn't loud enough to cover up that noise. It's LOUD!

I paid more attention to the noise today and I've decided removing the driveshaft didn't help at all. It peaks at about about 50 mph and goes away completely the second I let up off the gas. It's really annoying and really makes it unenjoyable to drive the rig sometimes.

Any ideas/thoughts/suggestions? Anyone?

 

[DutchVDub]

no need for driveshaft change when going waggy d44

i can do the welding and axle building for you 150$ pending Josh lets me borrow his 220 welder again.

 

[Jawa]

Thanks Dutch - my timeframe is sometime before March, I'll hit you up.


Wow, nobody has any thoughts on the vibe/noise problem huh? That question is a bit off from the original purpose of the thread, so maybe that's it... or maybe my super long post at the beginning is scaring people off! :doh:

 

[YELLAHEEP]

No, it's just that you can verbally describe the problem until you're blue in the face....... but it's so much easier to accurately diagnose when we actually get to hear/feel the problem...... otherwise, it's just a bunch of armchair quarterbacking.

The other thing that would REALLY help is if folks would get in the habit of putting all of their modifications/parts/specs about their rig in their signature. Giving a somewhat educated answer based on knowing how your rig is set up keeps all the "shot in the dark" suggestions to a minimum. For example, if your rig was using a stock driveshaft and 1" t-case drop and that were listed in your sig, we might be inclined to suggest that as the vibration problem. To the reader that doesn't have carnal knowledge of your XJ, all they know is that you have a lifted XJ, on 33's with a harmonic vib problem.

Hook up with one of us so we can give you an in-person opinion...... these 3 page threads of "it might be this, or it might be that" get kinda old......

Ya dig?

Since you're kinda up his way, you might get with Terry (87xjco) he's got tons of driveline experience.

 

[Jawa]

Yeah, I dig.

No, it's just that you can verbally describe the problem until you're blue in the face....... but it's so much easier to accurately diagnose when we actually get to hear/feel the problem...... otherwise, it's just a bunch of armchair quarterbacking.

I completely agree, but for some reason I thought it'd be kinda rude to post up asking someone to take a ride and tell me what my problem is. I don't know why I'd think that - everyone on here I've dealt with has been more than willing to help.

Hook up with one of us so we can give you an in-person opinion......

If you're volunteering I'll swing by. :thumbup:

Since you're kinda up his way, you might get with Terry (87xjco) he's got tons of driveline experience.

I was PMing with him about some gear setup work, I suppose it wouldn't hurt to ask.

 

[YELLAHEEP]

If you're willing to make the drive down, I'll make the time.

Gawdamn I'm a nice guy........

 

[DutchVDub]

Hey Jawa, where you located anyway? I'm moving into Firestone this weekend (H119&I25, Longmont exit) so if you're near me and want to drive over let me know. I'd be willing to take her out for a spin and help diagnose the problem. I'll even wear my nitrile examination gloves.

 

[Hypoid]

He's in Aurora, over by Stang5lgt.

 

[Jawa]

Yup, less than a mile and a half from him. I'd be happy to have you take a drive with me, but with the weather that's headed our way it won't be for a week at least I'd guess...

 

[DutchVDub]

whats wrong with the weather? if i can load a 26' uhaul and then drive it to my new house and unload it tomorrow, then you can come up and let me take a look at your rig. while you're there you can grab a box or two.