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I'm also enjoying the build!! I hope your nerve pain gets better. I take Gabapentin for mine and it's been a pretty big help. Might be worth looking into if your not already taking it.

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Discussion Starter #104
I'm also enjoying the build!! I hope your nerve pain gets better. I take Gabapentin for mine and it's been a pretty big help. Might be worth looking into if your not already taking it.

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I was on it for several years, but some blood test came back weird and they took me off it. It helped my seizures too.
 

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Discussion Starter #105
Well, the trend of nothing going right is still active. I couldn't get the front axle apart, so I ended up taking them to a friend's house. I neglected to get photos, but same ole stuff. Used the cherry picker to lift them, backed the trailer into the garage, (that took a dozen tries) and took both the "good" one and the original to his place. He works as a mechanic by trade, so he can use the shop at work after hrs. Hopefully he can heat them up, and knock them out from behind with an air hammer.


Today, I decided to give the rear axle a try. It laughed at me... Broke a bolt off in the caliper bracket for the left side. Then I discovered what was inside...





Holy crap, I was driving this in the green CJ5 up till I tore it down to build this CJ7.

Now, I do remember the green Jeep having a vibration in the rear when I was driving it. I figured it was the pinion bearing not getting enough oil due to how far the housing was rotated. I think I was right about that. It won't allow the carrier to rotate so I can get to the cross pin, or "c" clips... If you grab a rotor, you can twist the axles,and see the carrier try to move, but the pinion is frozen.

Can't even budge it with my tanker bar.



Any ideas here? Or will I end up letting Ryan take this one apart too...

By the way... notice the nice repair job on the yoke... 3 bolts one size, 1 another. I'll change that out anyway as I'd rather have the u-bolt type than the strap type.



How the hell do you get an axle apart when you can't rotate the carrier?
 

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Discussion Starter #106
The good news is the pinion now turns. The bad news is, it doesn't matter...

I took off the yoke, put back on the nut, and gave the pinion couple good raps. After that I could turn the diff no problem. I got the crosspin bolt out, and started to remove the pin. Bang, all progress once again came to a screeching halt. The ring gear is so fat, it's in front of the crosspin. The pin only came out a bit,and smacked into the teeth of the ring gear, leaving me to wonder hoe the hell they put it together...



I looked inside, and sure enough, without getting the pin out, I don't see how I can get the "c" clips out to remove the axles...



Really starting to hate these axles...
 

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Discussion Starter #108

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Discussion Starter #109
After another long break of nothing getting done, Jeep money going to other things, (OK one was a project gun) and a bunch of crap going wrong (including all this virus crap) I'm back at it. I'm halfway through another round of physical therapy on the shoulder, and it's going much better. Should be after almost a year...

Problem I had getting the front axle apart was I couldn't get the spindles off the knuckles. Took the old housing, and the replacement junkyard one to a friend from my off road club, who is a mechanic by trade. He was able to use a torch to heat it, then knock them out from behind with an air hammer in the shop after hrs. Of course, it took me forever to get back up there to pick them up once he did...



So, I get all the parts home, and now I have the remains of almost two complete units to go through.



I won't be using the 4.88 gears, of the originals, but the 3.55s of the junkyards unit are in fine shape. This will also get me a comfy 1,925 RPM @55mph and 2,450 @ 70mph when cruising down the road on my 35s... Before, it had 33s, and 4.88s, and would turn over 3K doing around 55 or 60mph. I started looking up all the seals, bearings and goodies I'll need to rebuild it, but with typical off-roader enthusiasm... first thing I ordered was an Eaton Trutrac... lol.

Here you can see the splines on the outter that blew when the axles was still in the old CJ5, next to the nicer axle from the replacement junkyard unit. It looks to be not boogered up too awful bad, and could still serve as a spare, so It will be cleaned up and taken along with...

 

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Dinkerdoodledoo
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Hey SSG,

I hate to say it, but drop 100lbs (fuel weight) into the back of your tub and give us a pic of your rear shackle.



You want it angling back, not forward, about 2- 10 degrees at rest depending on how much "give" you want it to have. In other pics with more weight on it, it looks like it hasn't gone back, but forward.

The way it is now, if you stuff a tire, it will lock forward into the frame and not reset.

It will also ride like shit.

You really want to put the shackle hanger back where it was and use a 1" longer shackle for the springs. I also have some Currie "slick rock" shackle hangers floating around if you want them. They're one piece and do not bend open like the factory ones. I also have longer "boomerrang" shackles I can send.

Send me a pm with your address, I'll mail em out.

Out,
CW02/CDR Grendel :flipoff2:
 

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Dinkerdoodledoo
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Two CJ's we did. You can see the shackle angles. Happy to zoom and cut if you need it?

Both jeeps ride really well and have YJ springs in the rear, with SJ springs in the front.

My wife liked the rims on the orange one... don't judge.
 

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Discussion Starter #112
Two CJ's we did. You can see the shackle angles. Happy to zoom and cut if you need it?

Both jeeps ride really well and have YJ springs in the rear, with SJ springs in the front.

My wife liked the rims on the orange one... don't judge.
Thanks. As you can see, this was just a test fit of an empty tub with no seats, roll bar, top seats... the fuel tank isn't even in it in that shot you quoted. I'll have to look into that.

The tub is back off, and the tank back out at the moment, so I could start in on the axles. I can't do any weight testing til I get them done and back in. That's not gonna be for a a while with me on the "couple of parts every now and then" payment plan... I should be able to get most of the parts to get the front axle back together later this month, then I can do the rear in the next couple months.

I was worried about the YJ springs being very soft. I was actually hoping they would be as soft as everyone says... with my back issues.
 

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Dinkerdoodledoo
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Thanks. As you can see, this was just a test fit of an empty tub with no seats, roll bar, top seats... the fuel tank isn't even in it in that shot you quoted. I'll have to look into that.

The tub is back off, and the tank back out at the moment, so I could start in on the axles. I can't do any weight testing til I get them done and back in. That's not gonna be for a a while with me on the "couple of parts every now and then" payment plan... I should be able to get most of the parts to get the front axle back together later this month, then I can do the rear in the next couple months.

I was worried about the YJ springs being very soft. I was actually hoping they would be as soft as everyone says... with my back issues.

Thing is, all the weight you mention won't move it enough.
 

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Discussion Starter #114
Having the front axles apart is nice, but what's even nicer is payday. My Eaton Trutrac came in from Summit Racing, and I started hitting up Auto Zone for the small parts, like bearings, seals... Being a cheep guy, I'm getting just enough at a time to get my point each time I go into town. Today I got one set of wheel bearings, races, and an inner seal for one of the front rotors to get my 5th point, and when the new rotor comes in tomorrow, I can get $20 off on it. I had to drop off the knuckles at a local shop to have the old ball joints pressed out, and new ones installed, as I have no press.
 

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Discussion Starter #115
So I'm looking, and looking, and I can't for the life of me find bearing, and seals that are made in the USA. Damn NOTHING is made in the USA anymore. Really starting to tick me off. Took my front rotors in to NAPA to get them turned today, and checked there too. Made in Spain, Denmark, everywhere but the USA. At least it's not china or mexico... and their does have a 3 year warranty, so I ordered a bunch from there, and I'll take the mexican crap back to Auto Zone tomorrow.

Also picking up a CJ7 hard top tomorrow. I put out feelers for a swap as my CJ7 came with a YJ top. Real PITA seeing as it doesn't have the proper YJ tailgate to go with. The guy wasn't using it, it was just sitting in his barn. He wanted to sell, but agreed to swap just to be nice. His way of saying thank you for me being a veteran. Cool. So I get home and go to get mine ready to take up tomorrow... Problem. I had taken the hatch off mine, and stashed it in the shed so it wouldn't get broken. Guess what? I can't find the bolts to put it back on. Every single nut and bolt in the hole build is up in the garage in marked baggies... except these. Well, I message the guy (facebook) and tell him of the problem. I'm hoping like hell he won't mind seeing as how he's not gonna use it anyhow. The dude says "just come get this one, and sell yours to help with your Jeep." Holy cow. He's GIVING me a CJ7 top. Now it's not perfect. It's been repaired where the hatch hinges are, and there's a hole from a bubble light because it came off a plow Jeep, but, I ain't gonna turn down free parts... So glad I sat and talked with them for a while today.

Next thing. I go home and start in on the housing. Gotta clean it up to get ready for the new parts coming in. I notice something... the junkyard housing I got to replace my slightly bent original... isn't the same. The spring mounting surfaces are the same. The width is the same. they both use the same brakes, spindles, knuckles... but the old one has thicker wall tubing. It's only got the slightest little bend, from jumping real hard, so now I'm thinking maybe I should just get that one straightened, and use it. I won't be jumping, so the thicker wall tubing would be good insurance for me. Probably need different seals and bearings... Carrier fits either, so I guess a Dana 44, is a Dana 44... Gotta think on it, and see.

Old axle housing I blew the hub on.


Junkyard replacement I had to get because I couldn't find a spindle anywhere.
 

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Dinkerdoodledoo
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So I'm looking, and looking, and I can't for the life of me find bearing, and seals that are made in the USA. Damn NOTHING is made in the USA anymore. Really starting to tick me off. Took my front rotors in to NAPA to get them turned today, and checked there too. Made in Spain, Denmark, everywhere but the USA. At least it's not china or mexico... and their does have a 3 year warranty, so I ordered a bunch from there, and I'll take the mexican crap back to Auto Zone tomorrow.

Also picking up a CJ7 hard top tomorrow. I put out feelers for a swap as my CJ7 came with a YJ top. Real PITA seeing as it doesn't have the proper YJ tailgate to go with. The guy wasn't using it, it was just sitting in his barn. He wanted to sell, but agreed to swap just to be nice. His way of saying thank you for me being a veteran. Cool. So I get home and go to get mine ready to take up tomorrow... Problem. I had taken the hatch off mine, and stashed it in the shed so it wouldn't get broken. Guess what? I can't find the bolts to put it back on. Every single nut and bolt in the hole build is up in the garage in marked baggies... except these. Well, I message the guy (facebook) and tell him of the problem. I'm hoping like hell he won't mind seeing as how he's not gonna use it anyhow. The dude says "just come get this one, and sell yours to help with your Jeep." Holy cow. He's GIVING me a CJ7 top. Now it's not perfect. It's been repaired where the hatch hinges are, and there's a hole from a bubble light because it came off a plow Jeep, but, I ain't gonna turn down free parts... So glad I sat and talked with them for a while today.

Next thing. I go home and start in on the housing. Gotta clean it up to get ready for the new parts coming in. I notice something... the junkyard housing I got to replace my slightly bent original... isn't the same. The spring mounting surfaces are the same. The width is the same. they both use the same brakes, spindles, knuckles... but the old one has thicker wall tubing. It's only got the slightest little bend, from jumping real hard, so now I'm thinking maybe I should just get that one straightened, and use it. I won't be jumping, so the thicker wall tubing would be good insurance for me. Probably need different seals and bearings... Carrier fits either, so I guess a Dana 44, is a Dana 44... Gotta think on it, and see.

Old axle housing I blew the hub on.


Junkyard replacement I had to get because I couldn't find a spindle anywhere.

You are way over thinking this.

Newer shafts are thicker. Take bigger 297X ujoints.
 

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Discussion Starter #118
Picked up my knuckles today with the new ball joint pressed in. Couldn't resist a test fit...



Also picked up my free CJ7 top. Turns out the 2 little holes where the woopie light was won't be much of a problem. I can either just silicone them, or put one of my leftover Army woopie lights there... The back hatch... well, that may be a different story. That falls squarely in the "What did you expect for free" category. It works... but it's not long for this world. It's been repaired on the top by the hinges, saw that yesterday. What I didn't see was the inside... It's gone... It will need replaced. I can still sell or trade my YJ top. Maybe take the hatch, and glass out of this to make a hard top bikini top for the summer...



 

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Discussion Starter #119
So, I jumped on the cragslist, and facebook sale groups in my area last night looking for a hatch for a CJ7 hard top. I figured I could sell my YJ top later to make up for buying one. Hell, I don't even remember how I got sidetracked into looking into tops, when I'm supposed to be buying parts for the front axle... I guess my TBI gave me some ADHD, but it's in my head now.

Never did find one, but I stumbled on something that made me think I may not need a CJ7 hatch... a YJ tub. This was 3 hrs away, but it was in way better shape than the CJ7 tub I went 3 states away to get. With the YJ style tailgate, I can just use my YJ top that came on my CJ, AND not have all those rust holes to fix. There's one issue, the trans tunnel has a little section missing because he was running a 700 HP big block Ford, C6, and 1 tons, but everything else is solid. Oh, and the glass is cracked in the windshield, but I have a 2 CJ windshields.

Talked to the guy, and he took it off the frame last night. I went down today and picked it up, along with the gas tank, since it feeds from the drivers side. Got the roll bar, power brake upgrade... and the chance to take apart, and clean a tub all over again.

Now I will be selling my CJ7 tub, and some associated parts to help offset what I just spent. (new kitchen roof money) In the end, I thing this will work out a lot better. I suppose I could still use the freebie CJ hard top. Seeing as the hatch is FUBAR, I could take it off, and the side glass out, and have a hard bikini top for the summer. Gotta have my shade.

 

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Discussion Starter #120
I'm still missing 1 seal, and 1 race, (both on order) and the rotors are still getting new studs pressed in, but I've just about got what I need to reassemble the main axle. I ran out of money, so no new brake pads or calipers... yet. Not like I'm going anywhere in it soon. Down in the back pretty bad though right now, so probably take some time off before I get to cleaning, and prepping the housing anyway.

 
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