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Damn, sorry to hear about the engine. GLad you are moving right along on the axle though.
 

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Discussion Starter · #602 ·
Pushing forward with the rear regear, I'll get to ripping apart the engine after I get that done, need the space that parts for the regear are currently occupying.

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Oh no he didn't! OH, yes I did. Thats a T&D pinion depth checker. Got tired of the multiple setups, so this will minimize it. I know that I'll be doing another set of axles for myself, plus I know of a few other people that will be bringing theirs to me as well. And those that will bring em to me will end up throwing me some cash to do it, so this thing will end up paying for itself. Itll do it for me alone. Time is money. At least the pinion from USA standard has the checking distance on the head for the c8.25. Didnt have it on the D30 set. Now hoping that there is no ring gear runout. Ill be checking for that first thing after installing the carrier back in the housing.
 

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Discussion Starter · #603 ·
Alright, got the ring gear installed on the carrier and had minimal runout, so I'm good to go! I'll be making some setup bearings for the pinion and checking everything out. I have a great starting point, so well see how it goes.
 

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Discussion Starter · #604 ·
First setup is really close, pinion needs to move in deeper slightly. I literally did use the factory shim, .029". Thats what I calculated with the tool anyway, the checking distance marked ob the head of the pinion is for the backside of the pinion, so its a little harder to go off that, cause then I'm measuring the pinions head with calipers, dont know any better way. But a little deeper is what I need, think I'll go with .003" first and see what I get
 

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Discussion Starter · #605 ·
Here's the pattern I got with third attempt, the second attempt, I literally added .005" shim and it pushed the pinion deep into the toe of the ring gear. This setup had .030" behind the pinion.
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And below off to the left of the pic is the coast side. The drive pattern pictured to the right in the photo below is the first attempt.
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After installing the service bearings on the pinion, it pushed the drive pattern slightly into the toe, which is good, was planning for that to happen. Pinion gear is buttoned up all the way, preload is right at 16in/lbs, didnt go crazy high this time since I now have a diff spec sheet from yukon.

Tonight I plan on grinding down some ring gear teeth to get the cross shaft in its bore, little bits at a time. After thats done, its time to do some cut and weld in the jeep to get some new springs underneath it.
 

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Discussion Starter · #606 ·
Had a change of plans, the forecast for the week played a factor in it, but since this afternoon/evening was so nice, I decided to tackle the leaf spring problem.

The passenger side spring was definitely shot, more so than the driver side, had to get a little happy with the torch, eneded up cutting the spring out the way to make some room.
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Opened up the nut housing like a tin can.
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Driver side done
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Passenger side done
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So its ugly as hell, but it'll hold until I dont need it to anymore.

I noticed that since everything just wants to rot out on my jeep, I need to add a support across the frame to the rocker panel to hold the front hanger. Its bad, everything's loose, and I suppose it's time to make my own rock sliders to strengthen up that area as well.
 

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Been there did that. I cut out my rockers and welded in 2x6 square tubing with a rub rail added frame stiffeners and replaced my floors not all at the same time, but I did write ups on all of it here. It's well worth the effort if you got rust and are trying to preserve.
R&R springs suck. But the worst is over. Carry on soldier!
 

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Discussion Starter · #608 ·
Been a minute, but I have the axle gearing done. New leaf springs are on, just need to start engine tare down now.

Everything is even now, just need to add strength to the mounting brackets, I have 1/4" plate which is 4" wide for this.
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Outwit the old, in with the new. New studs for the rear axle, they were shot on multiple levels.
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Final assembly pattern check. Wanted to make sure the pattern didn't run off the ground down teeth to install the cross shaft, and we're good to go!
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Now im just waiting for them to get 8nto the engine tare down, just dropped a 99 tj off to a friend yesterday, next weekend is booked up for work for the pole barn... so maybe if I get outa work early next week, I can start by pulling the engine hopefully. I gots too much going on right meow.
 

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Discussion Starter · #609 ·
I also have all the items I need to put my wheel tire combo together, just got the boltless beadlocks the other day last week. I suppose I'll work on those while the shop has my block......

I can't wait to have this all done, hoping that I dont have another engine failure after I'm through with this.
 
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