Lifting and modifying the YJ...

[Old Fart]

Not as bad on the YJ as it is on the TJ's (attaching the shifter to the body??????????), but yes - should be something you're familiar with.

[pdw]

Not as bad on the YJ as it is on the TJ's (attaching the shifter to the body??????????), but yes - should be something you're familiar with.

I've never had this problem with my t-case. But I have had it apart two or three times now-SYE kit, Tera 4:1 kit, etc, so I guess that I have been lucky!

Do what Ol' Fart says before you have to tear the whole thing out and apart again.

[USMC 0369]

I got my problems figured out.

First, as suggested...

I measured the depth of my new rear housing for the selector shaft.



Then I measured the shaft at maximum extension out of the housing.



Doesn't take an Einstien to figure out I had a problem. So, I measured twice and cut once. I measured the depth at 7/8 of an inch and marked the shaft at 13/16 to allow a small margin of error.



and another picture with the shaft withdrawn into the housing fully:



My other problem was that I put the 'syncro sleeve' onto the output shaft backwards. :oops: soooo, thanks for the good advice and now I can continue with other parts of the project. Cycling it through the gears didn't help, so I tore it apart again and started to reference an article on Moab Jeepers website about rebuilding the 231 (to stock). The problem I had was that the picture describing 'install of the synchro sleeve' was backwards too! The words had it right, but I went off the picture. duh....

[USMC 0369]

...and we're back.

The saga continues...

Did you ever have one of those projects that sort of expands on it's own?

So today I got the entire T-Case put back together, but it's still a little sticky when shifting through it's gears. I think I just need to put some more ATF in it and get it moving again. Should be okay.

[CENTER][SIZED]http://images33.fotki.com/v1072/photos/9/9459/4116941/NP231031-vi.jpg[/SIZED][/CENTER]

Next it's on to the rear axle. Now...I came across a Super 35 kit (thank you again) and plan to use it in the YJ. And I'm shaving off the old brackets and what-not. Relocating the shock mounts and putting new spring pads on with proper pinion angle so I don't have to use shims.

I'm sure some of you are scratching your head wondering why someone would do this much work for a D35. Lets just call it practice mkay?

So... I take the rear diff cover off the D35 and plop, plop....something is dropping into the drain pan with the gear oil. What could it be???

[CENTER][SIZED]http://images31.fotki.com/v1057/photos/9/9459/4116941/D35upgrade006-vi.jpg[/SIZED][/CENTER]

Thanking my stars that this didn't blow up on us at the last Gold Mountain trip [in the snow]...I was contemplating if the axle just didn't like me and was plotting to explode during a it's first return trip to Calico in Feb.

The spider gears were chewed up something fierce. This is what failed the last time we went to Doran.

[CENTER][SIZED]http://images33.fotki.com/v1073/photos/9/9459/4116941/D35upgrade007-vi.jpg[/SIZED][/CENTER]

My set-pin [bolt, shaft, thingy] looked a little torn up too...but I couldn't locate the rest of it, even after cleaning out the housing completely.

[CENTER][SIZED]http://images32.fotki.com/v1046/photos/9/9459/4116941/D35upgrade005-vi.jpg[/SIZED][/CENTER]

Well, no use in dwelling on the 'might have happened'. I set to work shaving off all the old brackets...

[CENTER][SIZED]http://images34.fotki.com/v1079/photos/9/9459/4116941/D35upgrade008-vi.jpg[/SIZED][/CENTER]

I really should take better pictures...when I remember to take them at all.

Here is my current dilema: I'm going to need an install kit & instructions for the Super 35 kit... anybody have a part number for that? I looked on Superior's website, but it was very little help. I googled it, but could only find whole kits for sale...

[pdw]

Did you call the folks over at Superior Axle?

MAYBE, just MAYBE you might be able to transfer everything over from axle housing to axle housing. But, somehow I doubt it......

[USMC 0369]

Did you call the folks over at Superior Axle?

MAYBE, just MAYBE you might be able to transfer everything over from axle housing to axle housing. But, somehow I doubt it......

I wasn't able to get ahold of the guys at superior yet. But I'm working on it still. I think I actually can swap everything over, but will need a master install kit for the R&P... (crush sleeve and shims, oil retainer, etc).

I plan to call again today when I get to the garage.

Also got the name of a good local place that deal in Superior products, plan to contact them in regards to the new 4.88 gears I need in the front D30. So by the time I'm done here...[reminds me, ask about getting extra crush sleeves]...I should know my way around putting in new R&P pretty good.

[pdw]

I wasn't able to get ahold of the guys at superior yet. But I'm working on it still. I think I actually can swap everything over, but will need a master install kit for the R&P... (crush sleeve and shims, oil retainer, etc).

I plan to call again today when I get to the garage.

Also got the name of a good local place that deal in Superior products, plan to contact them in regards to the new 4.88 gears I need in the front D30. So by the time I'm done here...[reminds me, ask about getting extra crush sleeves]...I should know my way around putting in new R&P pretty good.

When I was looking at the pictures of your R&P, I thought "What have you been doing with/to your Jeep?"
But, it is at least 10 or so years old and anything can happen....I would assume that the gears from the "donor axle" are in better shape?????

[USMC 0369]

I would assume that the gears from the "donor axle" are in better shape?????

LOL... yes, certainly they are. It's a Detroit Locker with 4.88 gears.

NEWS -

I'm researching getting 4.88's for the D30 front and install kits for both the new D30 gears and to install the Super 35 kit into the rear. Cost is a big deal to me, but customer service after the sale has to be there too.

I'm shopping for Superior R&P and install kits [D30 & D35] because of the OVERWHELMING endorsement of thier products by people I consider highly knowledgeable. Yukon and others are cheaper, but do I really want to have to do this again in 6 months?

I called Superior Axle to get the product numbers I would need for these items.
D30 R&P [reverse cut]=D30-488R
D30 rebuild [master install] kit=35-2032
D35 rebuild [basic install] kit=25-2049

So far my shopping has produced this:

4wheeldrive hardware
D30 R&P: $169.99
D30 rebuild: $54.99
D35 rebuild: $79.99
Tax: ???
S&H: $27.94
Total: [COLOR="Red"]$332.91[/COLOR]
*note - rebuild/install kits are Alloy USA, not Superior. Customer service sucked - as per usual - and instead of looking up the part numbers for the Superior equivalents, spent more time explaining that all the kits are basically the same and feature timken bearings...blah, blah, blah...


Mad4WD.com - recommended as good place, but I can't find only R&P sets or install kits on thier website. I also can't reach anyone on the phone as they are doing some remodeling [according to recording].

4WheelersSupply.com - has:
D30 R&P: $185.33
D30 rebuild: $68.09
D35 install kit: $63.86
Tax: none
S&H: none
Total: [COLOR="Red"]$$334.14[/COLOR]
I spoke to Shane, VERY helpful customer service. I actually will probably go with 4Wheelers version of install kit because it is more complete. Cost is 84.95 Also, 4wheelers doesn't charge sales tax or shipping for anything on their website except in house built axles and tires.

Of course everyone knows Quadratec:
D30 R&P: $169.99
D30 rebuild: $94.99
D35 install kit: $54.99
Tax: ???
S&H: 34.99
Total: [COLOR="Red"]$354.96[/COLOR]
Did not call customer service, Quadratec's website is always easy to navigate and pretty comprehensive. But they're just more expensive.


Last place I checked was redrock4x4.com:
D30 R&P: $157.95
D30 rebuild: $
D35 install kit: $
Tax:
S&H: $
Total: [COLOR="Red"]$[/COLOR]
Had to call customer service for Redrock, couldn't find the install kits online. This doesn't mean that thier website is bad, it's probalby just me. I'll edit and update later.

Sorry to make such a long drawn out post...it's mostly for my own gathering of information.

[NAILER341]

call quadratec, and talk to rob.
tell him i sent you.
lets see where they com in.
pm me the price he gives you.

[NAILER341]

i made the call for you.
pm me for the price, and info to get it done for a significant savings.

[USMC 0369]

Sent you a PM.

Thank you for the leg work!

[USMC 0369]

Frick! Frick! Double Frick!!!

Okay, so I'm having a really crappy day.

First...I'm shopping for some parts [see previous post], but my point of contact got off work before I could get ahold of him. No big deal, I'll just try again tomorrow. Still, the day was not as smooth as it could be.

Next...I'm working on the D35 rear axle...I've got the axle cleaned up (looks chrome) and I put it back onto the new spring pads in order to start measuring for center...and the wind starts to pick up and I'm not kidding when I say that the piece of paper I had written down the measurements for placement of the spring pads blows off into the desert!!!
So...please, does anyone know where I can get the correct measurements for the spring pads to ensure I get the pumpkin centered under the Jeep? Using leaf springs.

THEN! I look at the spring pads themselves sent to me by Currie. There are two sets but they're slightly different. I'll call them tomorrow to figure out what's going on, they're good at customer service.
[SIZED]http://images31.fotki.com/v1041/photos/9/9459/4116941/YJLift002-vi.jpg[/SIZED][SIZED]http://images33.fotki.com/v1070/photos/9/9459/4116941/YJLift006-vi.jpg[/SIZED]

Enough dealing with the rear D35...
So I move onto the front Dana 30, shave off the shock mounts with a torch and get ready to start grinding the slag off when I notice the tag for the pumpkin says that the gears are 3.55!!!! My jaw about dropped to the floor. Now I must search for a 3.73 carrier for the D30...
[SIZED]http://images31.fotki.com/v1083/photos/9/9459/4116941/YJLift004-vi.jpg[/SIZED]
I did an eBay search, but all carriers had no internals. Will my current internals swap over to the new carrier? Did 3.73 come standard in any vehicles that I should seek out at the junkyard? Help is always appreciated.

About this point I put the tools away and came home. I'm waiting for the house to catch fire or something.

[NAILER341]

Okay, so I'm having a really crappy day.

First...I'm shopping for some parts [see previous post], but my point of contact got off work before I could get ahold of him. No big deal, I'll just try again tomorrow. Still, the day was not as smooth as it could be.

Next...I'm working on the D35 rear axle...I've got the axle cleaned up (looks chrome) and I put it back onto the new spring pads in order to start measuring for center...and the wind starts to pick up and I'm not kidding when I say that the piece of paper I had written down the measurements for placement of the spring pads blows off into the desert!!!
So...please, does anyone know where I can get the correct measurements for the spring pads to ensure I get the pumpkin centered under the Jeep? Using leaf springs.

THEN! I look at the spring pads themselves sent to me by Currie. There are two sets but they're slightly different. I'll call them tomorrow to figure out what's going on, they're good at customer service.
[SIZED]http://images31.fotki.com/v1041/photos/9/9459/4116941/YJLift002-vi.jpg[/SIZED][SIZED]http://images33.fotki.com/v1070/photos/9/9459/4116941/YJLift006-vi.jpg[/SIZED]

Enough dealing with the rear D35...
So I move onto the front Dana 30, shave off the shock mounts with a torch and get ready to start grinding the slag off when I notice the tag for the pumpkin says that the gears are 3.55!!!! My jaw about dropped to the floor. Now I must search for a 3.73 carrier for the D30...
[SIZED]http://images31.fotki.com/v1083/photos/9/9459/4116941/YJLift004-vi.jpg[/SIZED]
I did an eBay search, but all carriers had no internals. Will my current internals swap over to the new carrier? Did 3.73 come standard in any vehicles that I should seek out at the junkyard? Help is always appreciated.

About this point I put the tools away and came home. I'm waiting for the house to catch fire or something.

damn, Nick!
that bites the big one.
try some of the local jeep shops. you should be able to pick up a dana 30 carrier for pennies from someones locker install.
post up in the wanted section on the various boards, or perhaps dig up a dana 30 lock right locker for the front. that will replace the innerds on the ebay carrier if you have to go that route.

good luck, man!
i'll check around for you a bit as well.

[NAILER341]

Nick, we need to talk about those gears. you want to go 48 in that thing, you'll be making a big mistake.
unless something has changed that i am not aware of, it is an automatic, correct?
48 is the wrong gearset! you need 4:10/4:11
hold off on placing your order.

what tire size do you plan to put on there? i think i remember hearing 35", please confirm.
lets discuss the build plan from the top, and see what you have in mind.
DO NOT ORDER PARTS.

[USMC 0369]

Erik! Thank you SO much for this new information.

Okay...let me understand and put this out public so others understand why everything has come to a screetching halt.

4.88 gears, with my auto tranny is going to put my RPM's WAY too high for daily driver/non towed rig. Thanks for catching that...4.10 is the new plan. And I'm going to edit posts below once I find good part #'s for the items I'll need.

And thank you also for finding me a 3.73 carrier for the D30 up front. I still owe you for IDTT 2005 helping me limp home the YJ after shredding the spider gears. Diet Coke right? What are we on...about six cases now?

This all started by buying new 33" tires... which rubbed on the fender wells and so I needed to lift the YJ to save the $$ invested on tires. Which led to the rear axle build-up, which made the front axle re-gear necessary. Of course if you're going to do any work on the D35 rear axle, you have to shave off the low hanging shock mounts...which led to new shocks and mounts and spring pads...

I hadn't ordered the parts. Thanks for catching me in time.
dang it! Currie isn't open on Saturdays.

I gotta get focused if I'm going to make it to the Calico Clean-Up!