For all those in the club running either YJ or XJ's with the vacuum disco. There is a relative simple solution to rid yourself of this and also get stronger ujoints.
1. Source yourself a set of 96 or newer TJ,XJ,ZJ or WJ. Inner and outer D30 shafts.
2. Remove your old shafts from the axles and separate from the unit bearings.
3. Reinstall your old unit bearings into the new shafts.(note...at this time it may be a good idea to replace the ujoints on your newly acquired shafts. I would recommend using the 760x joint instead of the 297x that came stock with these shafts as it has shown to be a much stronger joint.)
4. At this point you will need to remove the stock carrier. Make sure to mark your carrier bearing caps for side to side and top to bottom. Also mark the bearing cap bolts for the same. You will be reusing these. You want to put the carrier back to its original condition as not to change any critical measurements. You will need to remove the tie rod from the driver side knuckle to get the carrier out.
5. You will need to acquire one inner seal for the passenger side of the carrier. The national part# 4056S fits in very nicely.
6. You will need to press the new seal into the passenger side housing at this time. I found that a long extension coming through the carrier on the driver side with a socket large enough to sit on the metal body of the seal works perfect for this. Careful tap the mew seal into position insuring that it drives in straight. You want to press the seal in far enough that the beveled edge of the passenger tube coming into the carrier is showing. This will insure that when the new axle is slid into position the fat part of the axle is fully seated in the seal.
7. Now you can put the carrier back in and put all bearing caps and bolts and back in there original position. Torgue all bolts to factory specs. You can now slide your new axles into the housings and rebolt up your unit bearings to the knuckles. Check to make sure everything is moving correctly. Then simply rebolt up your cover and add fluid. Also at this time you cam rebolt up your tie rod to the drivers side.
8. Make sure all castle nuts are tighten down properly and wire jams are reinstalled on the tie rod and stub shaft nut.
This will now give you one piece axles on the passenger side and bypass the faulty vacuum disco unit. Also you will now have the upgraded ujoints.(the same size joints used on D44 shafts.)
Costs will vary. But expect to pay around 150 to 225 for a pair of good shafts and the dana/spicer joints will cost around 25 a piece. Do not waste your money on some kind of super joint at this time unless you upgrade to 4340 shafts as they will be to strong for the stock shafts.
Sat Jan 20, 2007 6:58 pm