dp96zj's Maintenance Thread

[zj95maxx]

yes, to get the C clips out, push the shafts in a bit and pull the C clips out. Might be a PITA with the cross shaft in there, I can't remember exactly what it looks like in there (been so long!)

check this out
http://www.mallcrawlin.com/forum/showthread.php?t=13071


For all I know, you might not be able to get the C clips out without the cross shaft out.. I don't remember

[dp96zj]

I just checked, and there's maybe 2mm between the axle shafts and cross shaft, so that's a no-go. how in the hell am i gonna get this out!?!?!?!?


Damn Jeeps!

[zj95maxx]

I just checked, and there's maybe 2mm between the axle shafts and cross shaft, so that's a no-go. how in the hell am i gonna get this out!?!?!?!?


Damn Jeeps!

Time for a dremel/plasma and a bunch of cussing and you can cut it all out.

Maybe you can find a mini, right angle drill, and drill the bolt out? might have to cut the carrier in half to get it out.

Screw extractor is something else to look into. I am sure there is SOMETHING you can do to get it out.

Or just swap the axle and be done with it!

[dp96zj]

I talked to my mechanic, he said he's dealt with it before, and that it can be done by putting a pick in there and trying to unscrew it out. I think that I could MAYBE do it, if I could find a screw extractor that I could work by hand. If I could hand drill or turn something to grab that bolt, it would probably work.

Where the bolt broke:


A pic from that writeup that shows the bolt, intact:



It looks like it broke right before it turns into the "pin" side, maybe 3mm of threads left would be my guess.

I have 3 options, IMO:

1: try to do it myself
2: take it to a mechanic
3: look for a new axle

I'll look into ways to do it myself, but so far that isn't looking too good. For option 2 and 3, I would have to put it back together. I don't have spare axles growing on trees, so it may be a while before I find a replacement.

Yes, I know, the ideal thing would be to replace it ASAP. However, I'm not sure what to do about it. Of course, this isn't the ideal way to fix it, but are there any objections to me putting the part of the bolt that I have back in, torquing it good, and driving with a soft foot? Of course, I wouldn't even think about taking it offroad until I get it solved.


[/rant]
[flamesuit]

[zj95maxx]

Get someone with a welder to tack a nut on top of that bolt..might work to thread it out.

[MoonWorks]

Get someone with a welder to tack a nut on top of that bolt..might work to thread it out.

Unless there is some of the bolt visable...that won't help anything b/c there's nothing to tack it to. And good luck getting the gun in there to tack it back together w/out it attaching to the carrier.

You're going to have to drill it out someway to get an easy out in there. Still going to be a bitch. You might be able to break it out as well. Depends on how much of the pin is still in there. I had one a LONG time ago that I ended up beating the cross pin enough that it finally broke the retaining pin. But you do have a chance of breaking the cross pin or the carrier.

[ATL ZJ]

Could you get a stud welder in there? like the kind used for body panels?

[dp96zj]

Unless there is some of the bolt visable...that won't help anything b/c there's nothing to tack it to. And good luck getting the gun in there to tack it back together w/out it attaching to the carrier.

That's what I was thinking.

Could you get a stud welder in there? like the kind used for body panels?

I haven't used one before, but if the area of the weld is smaller than the bolt it should work. I guess it would be worth a try if I could get my hands on one.


So I take it the overall consensus is that I should try and get it out immediately, instead of running with the broken off part screwed back in?

[jfowlzj95]

Theres one more 9" in College Station if you're really interested...

[dp96zj]

Theres one more 9" in College Station if you're really interested...

Is it in the junkyard or do you/somebody have it? Cause I'm most likely going 9" or 8.8 if I do the swap.

To keep everyone up to speed, I've decided to put the bolt back in, and baby it. I put a wanted ad on craigslist, and got a few responses with axles. One was for an 8.8 from a '98 exploder (he was gonna swap it into a stang, but found a bolt in axle). In the email, he said:

• he ground off the spring perches, and swaybar mounts
• drilled out the press-in retaining plugs
• cleaned up original disc brake stuff
• open 3.73
• found one bad carrier bearing, so most likely needs bearings/seals
• needs new pads/rotors

He said he'd sell it for $120

If Jon has a line on a cheaper, better 9" in CS, I may go that way, but this is looking like a pretty good deal.

[jfowlzj95]

It's a buddies 9" (he actually lives in Katy) but I'm storing it in my garage in CS, he's looking to get $150. He'd include new shoes and springs for the drum brakes.

That 8.8 deal you were talking to me about would probably be a better route if you're trying to get this done fast and cheap... unless you're really wanting the 9".

[dp96zj]

Well, just my luck, I get the old trackbar bracket off the jeep, and immediately see I can't get the bolt out with the lack of useful tools I have at my house. I take it to our trusty mechanic, he puts a hydraulic spreader (like the jaws of life) in it to pop the bolt out, and well...... nothing happens!!

I sent Kolak an email, and if I can get a stock bracket for REALLY cheap, I'll do that. Most likely, I'll try to sell my brand new track bar and get a TBC from KOR.

[dp96zj]

While I'm waiting for the TBC to be powdercoated, I wasted my time on some other crap.

• Put on shocks
• New brakelines
• New rear endlinks
• Seal rear diff back up
• Chop off exhaust
• Turndown after cat

So now it's back on all fours, and I'm waiting for the TBC to be mobile. After that comes, I'll adjust the trackbars one more time and drive it a bit. I need to weld the muffler back on since I cut that small section of pipe off, the cat/turndown is pretty dang loud.




______


Also picked this up today

[jfowlzj95]

Mmmm no muffler... AGLUGLGULGLGULGLUGULGULGULGULG...

[dp96zj]

Mmmm no muffler... AGLUGLGULGLGULGLUGULGULGULGULG...

Pretty much. I'm waiting for my dad to get home, I'm gonna scare the living shit outta him!

[DJJordache]

I hope your not going to leave the exhaust like that for a while..... it would need another exhaust hanger depending on if you still have the one at the crossmember.

and I have heard (internet hearsay so take it as is) about having a O2 sensor too near the exhaust ending that it get's confused by fresh air occationally getting to the sensor in off throttle situations. I dunno if it's true but FYI....

[dp96zj]

The plan is to take it to my mechanic and have him weld the muffler back on (then I'll bolt the turndown after the muffler) as soon as I get the TBC. Come to think of it, I'll need another exhaust hanger anyway, because that muffler is freaking heavy!

[dp96zj]

Got my 8.8 flange today, wow that was quick delivery! The trackbar conversion also shipped today, so the rig will be moving as soon as I get that on.

As for the new 8.8, I need to pull the carrier and change out one of the bearings, then put on the new flange, then clean it up and it should be ready for the brackets.

Extremely newb question here, but does anyone have any tips for holding the axle secure while I work on taking the carrier out? I had it resting on two jackstands, but as soon as I put force on the carrier, the axle came off the jackstand and my foot buffered its fall. If I was wearing Maxx's Jesus sandals, I would've been screwed.

I really have no other tools, one table vice and a few small vice grips. I'm thinking if I lay it on the ground and put a shit-ton of weight on top of it (maybe a jeep ), then that would secure it enough to let me work on the carrier.

[zj95maxx]

Get friends?

[Schwarttzy]

If I was wearing Maxx's Jesus sandals, I would've been screwed.

[jfowlzj95]

Are you trying to remove the cross pin so you can pull the shafts or the bearing cap bolts?

Whenever I work on an axle that's just in the open, I stand on the pinion and my weight seems to keep it from rotating. I'm only 190 lbs.

[dp96zj]

I pulled the axle shafts already, and the cross shaft is in there just to hold the spider gears together. I'm trying to take the carrier out, as a whole, because the guy who bought it before me took it all apart and saw that one of the carrier bearings was about to go. The trouble I'm having is that you have to pull 90* exactly straight up on the carrier to get it out, while keeping the axle housing stationary (which isn't easy while its on jackstands). I'll work on it Tuesday when I have a day off.

EDIT: I think I'll end up putting it on the ground, have someone stand on the housing, and give the carrier a good yank. If that doesn't work, I may try the pry bar approach.

[dp96zj]

boredom + sawzall + MC stickaz = today's mods


the section I cut off:


post-cut:








KOR TBC should get here on Wednesday, then it will finally be driveable!

[jfowlzj95]

Rear bumper cut looks familiar. You sure do have a bunch of stick on HP!

[dp96zj]

I got the KOR TBC yesterday, and installed it as well. Everything went really smoothly, no complaints so far, and can't wait to test it out!


Old vs. new (BEEF)



The reason why I had to replace the bracket:



Pic of front linkage:



How it looks now:



Definitely need to push the rear back when the 8.8 goes in:



Oh yeah, I also took the 8.8 to my mechanic and he helped me get the carrier out, now I just need to find a place with a bearing press to put on some new ones.