Rear axle woes

[COYOTE83]

Alright so I finally got all of my parts I’ve been waiting for and got the jeep in the shop for maintenance and upgrades. And I’m running into problems.

Info: 2001 sport with rubicon axles, rubicon lockers. 4.10

Issues: I’m Installing revolution axle shafts in the rear and when I removed the factory rear axles I found damage to the journal surface where the race fits in the axle tube on both sides from spun bearing races. Then I pulled the rear differential cover and found three chunks of what I’m assuming is part of the spider gears.

Questions:
since the bearing races aren’t a press fit, should I just install replacements or should I use green locktite? I’m assuming since it isn’t a press fit I should just clean and inspect surfaces and install the new ones without locktite.

The chunks of spider gear, should I just reinstall the old axles and hope for the best until I regear?
There’s really nothing I can do right now, I have to drive it. I just don’t want to install the revolution shafts and then grenade the differential and ruin the new shafts.
I’m waiting on revolution 5.38 gear kits to be in stock, so i’m thinking just reinstall the old axle shafts with some rtv on the seals and hope for the best until the regear kits become available.

Any advice is greatly appreciate.

 

[COYOTE83]

Just finished installing the Savvy body lift. Tomorrow I’ll install the cable shifter and maybe the Currie steering and assemble the revolution front shafts.
Just Gota figure out what to do about these rear shafts.
Hopefully I don’t find metal chunks in the front differential when I do the front shafts…

 

[Gollywomper]

Someone will correct me if I’m wrong. The rear rubicon locker does not have spider gears. It has a torsion driven lsd. It is a ticking time bomb if they have broken teeth.

 

[Gollywomper]

I would look to replace that locker before it goes and takes out your gears too.

 

[COYOTE83]

Ah ok. So…. I need to find a rubicon locker or pony up and get an arb.
A couple more questions, how hard is removing and installing either another factory rubicon locker or an arb? what’s the average time frame assuming everything goes as planned? (Which it won’t)
What should I do in the mean time? It’s my daily driver…
I’m thinking take the revolution shafts back out, reinstall the old axle shafts with some rtv on the leaking seals, that way if the differential goes it won’t damage the new chromoly axle shafts, and hope for the best?
Or should I hitch a ride to work and expedite this asap?

 

[COYOTE83]

I was really hoping this would go smoothly and I could get all of this done this weekend. It’s been nothing but bad news since I started taking things apart.
It’s got me paranoid about the rest of what I will find. I’m in the shop now about to do a full a fluid service on it. Hopefully no more chunks of metal in any oil….

 

[Gollywomper]

It may be difficult finding another rubicon air locker. They are all pretty well used at this time. For the price most ask for one you may be money better spent upgrading to a stronger locker. The arb will require a compressor.

 

[COYOTE83]

Right. I’d read something before about the front and rear rubicon lockers being the same other than the lsd, I’ll have to find the thread again and see if they are interchangeable to eliminate the lsd.

I’ll probably just have to upgrade now. I was not planning on this. This throw chunks of metal all in my plans.

Well, I’m about to go read a few threads on changing lockers and see what I’ve got myself into.

 

[COYOTE83]

First thread I read @Chris lists the tools needed and I don’t have any of the specialty tools, or the budget and time to invest in that right now.
So.

No telling when the revolution gear sets i need will be in stock, it’s already a week past the time frame they told me the last time I called.
I don’t have the time to acquire the tools and knowledge I would need to buy an arb and install it myself.
This is my daily driver.

I think I will have to reinstall the old axle shafts and take it easy driving it until I can get the gear kit and a new locker and compressor.

 

[COYOTE83]

This sucks.

 

[Gollywomper]

If you can find parts
To repair your Locker it simplifies the process some. Definitely sucks. I have been in your shoes and have had unexpected diff issues that were found during maintenance. Better to get them done sooner than later.

 

[COYOTE83]

So I’ve been doing some reading on some other threads about rubicon lockers and it brought up another question that I think is irrelevant to my current issue, but while I have a thread going asking questions about all of this, I’ll go ahead and ask…

I think my locker switches may be bypassed and independent. Can anyone tell me a test procedure to determine this?

 

[macleanflood]

Since it's your daily you might want to look for another TJ Dana 35...I've seen them sell for under $300 in my area (Pacific Northwest).

You can install the replacement while you fix your original...or build the replacement since it won't have spun bearings.

I just did a Super 35 kit on mine with an e-locker... highly recommend...finding the e-locker was a PIA... everyone is out of stock. Wiring was easy. No compressor needed.

-Mac

 

[williambmac]

No telling when the revolution gear sets i need will be in stock, it’s already a week past the time frame they told me the last time I called.
I don’t have the time to acquire the tools and knowledge I would need to buy an arb and install it myself.
This is my daily driver.

I've been trying to order their 5.13 gear package for quite some time. My phone conversation on 3/31/22, they told me the gears are 2-3 months out at the minimum.

 

[COYOTE83]

Since it's your daily you might want to look for another TJ Dana 35...I've seen them sell for under $300 in my area (Pacific Northwest).

You can install the replacement while you fix your original...or build the replacement since it won't have spun bearings.

I just did a Super 35 kit on mine with an e-locker... highly recommend...finding the e-locker was a PIA... everyone is out of stock. Wiring was easy. No compressor needed.

-Mac

Well, my lift is triangulated in the rear and the brackets are welded to the axle housing. I think I’m going to have to put the old rear axles in and chance my luck until I can get gears and a locker.

 

[COYOTE83]

I've been trying to order their 5.13 gear package for quite some time. My phone conversation on 3/31/22, they told me the gears are 2-3 months out at the minimum.

Maybe i should start looking at other options then. Dang it. I really wanted 5.38 and as far as I know they are the only ones that make 5.38 for my axles.

 

[williambmac]

Maybe i should start looking at other options then. Dang it. I really wanted 5.38 and as far as I know they are the only ones that make 5.38 for my axles.

Nitro gear sells them also, but they are also out of stock.

 

[Jerry Bransford]

I would look to replace that locker before it goes and takes out your gears too.

My rear locker's LSD is still fine despite what it has been through. Just have to not drive that axle unlocked on terrain that causes the rear tires to spin/catch/spin which can take the LSD out.

 

[someguysjeep]

you can work around some tools, but you need access to a press and a puller. or you can make set up bearings, they negate the need for the puller and press so often but they may still be needed for final assembly.

and not all traction devices hold the shims inside the bearings, some can be run outside.

 

[COYOTE83]

Thanks Jerry. Do you think I will be ok leaving the revolution shafts in for a few months until I can get a new locker and regear? Or should I use the factory shafts as a precautionary measure?