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**2000XJ** · 10-19-2009, 07:26 AM

Yet another weekend with some good wrenching. Ever since I did the disc brake swap on my XJ in January '09 I've been leaking diff fluid from the both seals. First it started on one side, then about a week or two later the other side started. Needless to say I was pissed because these seals were brand new.

Anyway, I ordered up a new set of bearings. seals, and preload spacers for my spare D44 shafts. I got the shorter of the two D44 shafts all setup to carry as a spare because the shorter shaft can be used on the long side as well to get you off the trail and home - whereas the long shaft only works on the long side. The XJ wasn't the DD anymore, so the gear oil problem wasn't huge - especially since when it got wheeled it got trailered at the time.

Well I've lost my trailer spot due to my friend's rig not being street legal, so since mine is I'll be driving it again to and from the trails. Time to fix this problem.

After some investigating, I realized that my problem was most like the preload spacer that is on the shafts for the disc brake conversion. The original spacers were fabbed up by a company in PA, and I don't think that they took into account the small lip that is on the axle seal, and the spacer ended up tearing that lip up a bit, which in turn caused the leak. I am hoping that it's as simple as this.

The spare set of spacers that I ordered was from Teraflex, and these spacers were filleted correctly and do not harm that lip. So I threw the spare shafts in, and so far no leaks, so if I'm leak from a month from now I'll be happy.

Doobie · 10-19-2009, 11:14 PM

Its a good thing you are so mechanically inclined. Why do you suppose the manufacture over looked the small lip?

**CT99XJ** · 10-20-2009, 12:17 AM

every time i look at this thread, i turn about as red as your XJ witn envy lol

**2000XJ** · 10-20-2009, 12:15 PM

Quote:

Originally Posted by Doobie

Its a good thing you are so mechanically inclined. Why do you suppose the manufacture over looked the small lip?

Anyone can be that mechanically inclined, just takes practice and patience. Trust me, pulling shafts used to take me alot longer when I didn't konw what I was doing. You only get better by practicing and having the inclination to tackle things yourself.

Honestly, he probably overlooked it for a couple of reasons. First, it's hard to fillet the preload spacer, which is essentially a ring, at the right angle and depth to have it set in there correctly. It also involves more time and patience, and it's pretty easy to overlook. He may have also not thought that it would've made a big difference.

Quote:

Originally Posted by CT99XJ

every time i look at this thread, i turn about as red as your XJ witn envy lol

Thanks! I'm finally getting to catch up with alot of little things on the to-do list that luckily don't cost too much to fix. Fixing the leaking axle was a big step in increasing my overall satisfaction with this rig - it was just too annoying.

I also finally got around to refilling my grease gun and greasing everything, so the controls arms, trackbars, driveshafts, ball joints, rod ends, etc are all greased, and I'm fully squeak-free again.

My next step is to do something about the steering. The Currie setup is great, but I'm not satisfied with the inverted-y setup. I also think that the steering box is on its last legs, so that will get some attention too. But that won't be until later on in the winter when I have some more cash to invest into a different steering setup, new box, etc.

**muddeprived** · 10-20-2009, 12:31 PM

Quote:

Originally Posted by 2000XJ

Anyone can be that mechanically inclined, just takes practice and patience. Trust me, pulling shafts used to take me alot longer when I didn't konw what I was doing. You only get better by practicing and having the inclination to tackle things yourself.

Honestly, he probably overlooked it for a couple of reasons. First, it's hard to fillet the preload spacer, which is essentially a ring, at the right angle and depth to have it set in there correctly. It also involves more time and patience, and it's pretty easy to overlook. He may have also not thought that it would've made a big difference.

Thanks! I'm finally getting to catch up with alot of little things on the to-do list that luckily don't cost too much to fix. Fixing the leaking axle was a big step in increasing my overall satisfaction with this rig - it was just too annoying.

I also finally got around to refilling my grease gun and greasing everything, so the controls arms, trackbars, driveshafts, ball joints, rod ends, etc are all greased, and I'm fully squeak-free again.

My next step is to do something about the steering. The Currie setup is great, but I'm not satisfied with the inverted-y setup. I also think that the steering box is on its last legs, so that will get some attention too. But that won't be until later on in the winter when I have some more cash to invest into a different steering setup, new box, etc.

I'll be interested in taking the currie system from you if it's still in good shape.

**2000XJ** · 10-20-2009, 02:03 PM

I'll keep ya in mind Mudd, if I decide to get rid of it to purchase something else

**muddeprived** · 10-20-2009, 04:09 PM

Quote:

Originally Posted by 2000XJ

I'll keep ya in mind Mudd, if I decide to get rid of it to purchase something else

Cool!

Doobie · 10-20-2009, 10:56 PM

BTW, Mud, Love the signature.

2000XJ

I am in the middle of my biggest dilemma. I am not sure if it is the RE5.5LA that I desire, or if it is the 4.5SF, like you have. What is your experience with the 4.5" and 33's?

**muddeprived** · 10-20-2009, 11:56 PM

Quote:

Originally Posted by Doobie

BTW, Mud, Love the signature.

2000XJ

I am in the middle of my biggest dilemma. I am not sure if it is the RE5.5LA that I desire, or if it is the 4.5SF, like you have. What is your experience with the 4.5" and 33's?

Why not get the 5.5" LA but use the 4.5" coils?

**2000XJ** · 10-21-2009, 12:32 PM

Quote:

Originally Posted by Doobie

BTW, Mud, Love the signature.

2000XJ

I am in the middle of my biggest dilemma. I am not sure if it is the RE5.5LA that I desire, or if it is the 4.5SF, like you have. What is your experience with the 4.5" and 33's?

Quote:

Originally Posted by muddeprived

Why not get the 5.5" LA but use the 4.5" coils?

Mudd hit the nail on the head. 4.5" LA is the way to go, IMHO. I love the height of the XJ with the 33's. It just works really well, and the COG is still nice and low. However, LA's and 4.5" would make me that much happier

Doobie · 10-23-2009, 01:16 AM

Does RE offer it this way? Or would it be s special order? The only reason I dont go for the 5.5LA is due to the price.

**2000XJ** · 10-23-2009, 02:03 PM

RE, and most RE vendors will send you whatever you want. Alot of TJ guys go with the 4.5" spring when they buy the LA kit. I'm sure the same can be done on XJs.

Doobie · 10-26-2009, 02:41 AM

hum.. i will have to look into that. thank you for the good idea.

**CT99XJ** · 10-28-2009, 12:32 AM

what steering box are you looking at for replacement?

**2000XJ** · 10-31-2009, 01:20 AM

I've heard many use the PSC box and OEM Durango boxes with great results. We'll see what happens though. I had a major failure last weekend on my drive home from wheeling. I had no carnage or breaks during the day, but the ride home was hell.

Just for the record:
Whenever I drive my XJ to a wheeling destination, at the end of the day I check over EVERYTHING. When I got into this sport I was driving home one day and felt like my tires were loose. Sure enough, my lug nuts had come loose. A wheeling veteran, who is also a friend of mine, told me that I should always check my rig top to bottom, front to back, and check ALL lug nuts prior to my driving home. The forces of wheeling can cause things to come loose.

BEFORE I drove this Sunday I did exactly that - something that I've been doing since the day I was told to do it - whenever I drive my rig home from the trail. All the lug nuts were nice and tight, all the suspension and steering componets were nice and snug, the XJ was ready for an uneventful drive home.

Here's a pic for you guys, better explanation to come in the next few days once I get re-settled from having been away for a week.

Nothing like changing an axle shaft on the side of a road before you even hit the interstate. The mounting holes on the rims actually wallowed out and chewed up the lug nuts, unit bearing, and unit bearing bolts

Then after 45 miles of driving on the interstate the rear wheel decides to sheer the lug nuts clear off the axle shaft flange and leave me to get to the side of the road on only 3 tires. Turns out these holes had wallowed out too causing the rim to fail and this crap to happen:

Now my hypothesis on this is: When I checked all the lug nuts and their tight-ness, it's possible that I was just tightening the lug nut further into the already wallowed out holes giving me the impression that I was getting them nice and tight. You don't feel loose lug nuts (at least in my experience) at low speeds.