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Discussion Starter #1
First off this is what I am running:
91 YJ 4cycl, Ford 9 rear, Dana 30 front(4.56 gears)(all stock i believe), ARB locker in front with 32 TSL's. Auto hubs.

The problem I am having is when in 4 wheel drive I occasionally hear a loud bang as if something is disengaging and engaging. I think it may be the auto hub but I'm not sure. I also have oil leaking out of the right front axle onto the inside of the wheel. I took the right front axle out and the diff. cover off and all the teeth on the viewable gears looked fine(oil seemed fine too).

Is there anything I should be looking for to diagnose this problem?

Also what seal do I need to change to fix this leak?(Inner axle seal just ouside the diff?)

Also I was under the impression that the drivers side front wheel always turns the differential gears? When I turn the front left the gears do not turn unless I have the locker engaged. Also when I have the locker engaged shouldn't both front wheels turn together? My right front wheel doesn't move when I turn the left front(engine off)?

Thanks for the help in advance guys.
 

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A few things come to mind.

1st. This is a CAD (Central Axle Disconnect) axle. The only way that the front wheels are going to turn together is with the engine running and 4wd engaged. (or at least with vacuum applied to the disconnect mechanism). It sounds like you are being cautious and not running this thing on jack stands, lets keep it that way.

2nd. Banging in this style front end may be in part due to the CAD actuator engaging the front two axle shafts. You may want to pull that actuator out and see if the splines on the inner shaft are AFU and not allowing the collar to slide over. Your "auto hubs" is simply a unit bearing that is always locked in. The only "auto" portion is the CAD Actuator (Read: junk).

3rd. The leak is coming from the seal at the outer axle shaft. You will need to pull the outer shaft (and all other parts to get to it) and pull out the actuator to get at the seal. The seal is a bugger, and I have no "easy" way to put one in.

What I would do in this case (and I dont have the seal number handy) is pull the vacuum stuff off completely, put a new seal in the hole at the CAD section (it is not the stock seal, there is a different one that works and I can not find it at this time), and stuff a TJ shaft in with a block off plate in place of the vacuum components.

Hope this helps.
 

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Discussion Starter #3 (Edited)
Thanks

Thanks, I just did some testing with the motor running. The CAD is only engaging with high RPM's and then disengaging sometimes at Idle. Shouldn't this have enough vacuum to stay engaged through all RPM's?

Is it much of a concern for wear and tear and increased drag by putting a TJ axle in that bypasses the CAD? A WARN hub conversion kit seems ridiculous at $1200...

Is there any particular TJ axle I'm looking for?
 

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No specific axle, just remember that you are going to have a larger u-joint on one side than the other.

And that is EXACTLY how the TJ's work. They are basically the same running gear without CAD.
 

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Discussion Starter #5 (Edited)
so do i need to get an outer axle and inner axle together because of the larger u-joint?, I can't use my original outer?, is there a way to put manual hubs on without the $1000 kits?
 

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Discussion Starter #7
am I going to have a difficult time steering on the road by eliminating the disconnect? Any suggestions on where to look for the axle?
 

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steering is not affected by this upgrade.
go to junk yards and look at xj's. most of em have it
 

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Discussion Starter #9
will the 97-01 cherokee axle work? is it anything from 1988 on up? what's the difference between the xj and tj axles(TJ bigger?)
 

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no difference. jeep axles either have the bigger size u-joint or they don't, so XJ shafts w/ the large u-joint are the same as TJ. You won't experience any handling difference either, u have an ARB so it'll be an open differentiall all the time untill you lock it on the trail. ur rig will probably wheel better because you may have been in 3 wheel drive a lot with your ARB locked and your vacuum disconnect not working..... that means you were in 2 wheel drive when the ARB was unlocked and your vacuum disco wasn't working.....

get some real front axles in that YJ!!!
 

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Yep thats too much. If I have any left I'll sell you one. Think I have some 30 spares around. Shoot me a pm if interested.
 

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Just in case

I have the complete D30 out of the front of my 1999 XJ available if you are looking that way. 3.07 gears (probably useless to you) and open. Disc to disc.
PM me if interested.
 

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Discussion Starter #14
There is what looks like a gear at the old vacuum disconnect where the old inner axle used to sit. Do I need to take this out and replace the seal at the vacuum disconnect when I put my new TJ axle in?
 
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