Louie4's YJ by Louie4

6 minute(s) of a 411 minute read

Got a new t-case this weekend.

I should have explained but I posted that pic before class started.

My old t-case has the stock chain and I think it is has a lot of slack due to the 307K miles and abuse I've put it through over the last 12 years. My front output yoke has about 1/8" of play in and out which I imagine is not good when the suspension cycles. On top of that I'm unsure what SYE I have. Tom Woods himself has told me he thinks it's his but I'm not sure. The rear seal is leaking but I don't know what seal to get for it.

Now onto the new case. A buddy brought it to me this past weekend. It was another friend of ours case who has a '95 that pretty much sat in a barn. They put a JB Conversions SYE in it and he wheeled on it a couple times then got an Atlas II.

I was offered the cast about 8 months ago and have just not been able to get it, free that is. I also got several spare front shafts (thanks Steven) and one is a solid pass. shaft for when I remove the CAD. As of now I have 2 good spares at my disposal. The stock shaft had been in there from '93 to 2012.

3-15-2013

Finally some progress. I went ahead and pulled the D30 out. I am replacing the pass. side seal and I think I'm going to paint it too.

Chopped off the sway bar bracket.

Starting to clean it up.

Here is how i installed my seal. I used the 1/2"-13 all thread with a 3/4" washer I got from ACE. I used an 8.8 side gear and one of the small D30 spider gears. Worked well enough with after fiddling with it.

3-16-2013

I got crazy today.

I got the axle painted, installed, took my old t-case out and put a new one in, and moved my bumpstops forward. I also did all the yard work in between.

Bumpstops. Probably can't tell but I drilled and tapped holes over an inch forward.

My old t-case and the new. This is the first time it's ever been out of the jeep.

I found that the speed sensor o-ring was leaking on my old t-case.

I need to get Tom Woods to send me the right yoke for my driveshaft.

Diff guard has taken a beating.

I need new gloves.

3-17-2013

Here is what I found. One of my u-joints is toast and pitted. There were needle fragments but mainly just dust. I do think the XJ ball centering kit would work.

3-18-2013

There is no doubt I can use the XJ CV joints after taking it apart. I will wait to see what TW says or I may look around some more for a new ball centering kit. I don't want to put a used one in if I'm going through the hassle of disassembling the entire shaft. I took all the other u-joint out and it was fine. I'll most likely replace them all though.

Here is a shot of the front axle under the jeep. It's not very good though. I got the tires on and all I need to do now is fill the D30 up with fluid.

3-21-2013

I got to go to the junkyard today and get a few things. I started to find different color speedometer gears while looking for a front driveshaft out of a cherokee or a grand and kept them hoping one would be the right tooth count. It looks like I got a 34 tooth which is what google says I need for 4.10's and 33's. My stock one is 30 tooth so it looks like I may have gotten lucky.

I also found one front driveshaft out a grand cherokee. It is in good shape too. I took the double cardan apart and merged it with my Tom Woods. I also put the Spicer u-joints from the cherokee shaft in because they were in good shape.

Here is the finished product. I also found out there was suppose to be a spring in the small post which my TW didn't have. I may have lost it years ago.

I also received my speedometer pinion o-ring and isolator bushings today.