I'VE HAD IT!!! What are my options?!?!

[91 Green YJ]

OK, quick back story. about a month after installing my lift, I blew out the rear U-joint (axle side) of the rear drive shaft. DS s[un around under there and beat the crap outta the bottom of the tub and the muffler. It also cracked the output housing on my NP231. OK, no problem. we went to Pep Boys and got a new U-joint. It was just a bit too loose, but we went with it.

About three weeks later I was drivin g down to New Jersey, I was on the Garden Sate Parkway doin about 80 when it blew AGAIN! So i stopped, picked up the driveshaft off the ground. Shoved the output yoke back in to the T-case, threw it in 4 HI and went on my merry way. Bout an hour later i felt the chain in the NP231 slipping, so i pulled over to find the yoke gone and the t-case smokin like George Carlin. poured some spare fluid in it and limped it home.

My mechanic recently (2 weeks ago) built me some custom u-joints and put em in. No problems at all until tonight when i was workin (delivering pizzas) and i felt that old vibe which was a sure sign it was getting ready to go. Luckily it was the end of my shift anyway. Jacked her up, and sure enough, WAY too much play!

The rear axle is not original. I can tell because it has ABS brake sensors in the drums with the wires cut. And I know ABS wasnt available in my model year (92) I know my SN is 91 but i goofed when registering.

Anyway, here is what the U-joint looks like now:
http://imagem.webphotos.iwon.com/1000065749/1000065749_9132003115437PM0.0595209

http://imagem.webphotos.iwon.com/1000065749/1000065749_9132003115438PM0.9231335

http://imagem.webphotos.iwon.com/1000065749/1000065749_9132003115438PM0.5129903

http://imagem.webphotos.iwon.com/1000065749/1000065749_9132003115538PM0.8894464
this ones kinda blurry, but you can see how the sides are getting worn down.
http://imagem.webphotos.iwon.com/1000065749/1000065749_9132003115538PM0.928291

http://imagem.webphotos.iwon.com/1000065749/1000065749_9132003115538PM0.2718099

As you can see, this u-joint is shredded. This is the THIRD TIME this has happened. Needless to say, I've had it. What are my options here? Custom Driveshaft? SYE? Both? what else?

[wrangleryj44]

hey man have you thought about gettign the drive shaft balaced or if the DS is to short and putting the UJs in a bind thats about all i can think of at the moment.

[91 Green YJ]

-=- originally posted by wrangleryj44 -=-
hey man have you thought about gettign the drive shaft balaced or if the DS is to short and putting the UJs in a bind thats about all i can think of at the moment.

Well i know the DS is out of balance after the first time the ujoints blew cause it got dented to ****. As far as being too short, is concerned, that could be. how could i check?

[wrangleryj44]

look at the shaft at the front of the DS and see how much of it looks warn or discolored it should have a line from shiny where it is actually in the seal and the part that is faded that is out of the seal if you get what im saying

[91 Green YJ]

You mean this? What do you guys think? too short?

http://imagem.webphotos.iwon.com/1000065749/1000065749_914200323814AM0.2406732

http://imagem.webphotos.iwon.com/1000065749/1000065749_914200323814AM0.4363781


dont ya just love digital cameras?:agree:

[Pollock]

I think something is telling you to put in a SYE with a CV driveshaft. :bsod:

[jeepnmike]

I think you are way overdue for a SYE and new CV driveshaft. I think you need to do that anytime you lift a Yj over 2 inches. Taht will cut down on your vibes and will give you peace of mind!:giveup:

[91 Green YJ]

-=- originally posted by jeepnmike -=-
I think you are way overdue for a SYE and new CV driveshaft. I think you need to do that anytime you lift a Yj over 2 inches. Taht will cut down on your vibes and will give you peace of mind!:giveup:

Yeah, problem is price. I know where I can get a SYE installed for 210 bucks. Now where can I get a CV Driveshaft that wont cost me 400 bucks? Because right now, I cant afford it.

[35xj]

you need to find a front XJ shaft and have it cut down to fit. Should cost about 50 bucks.

[will_m]

-=- originally posted by 91 Green YJ -=-
Yeah, problem is price. I know where I can get a SYE installed for 210 bucks. Now where can I get a CV Driveshaft that wont cost me 400 bucks? Because right now, I cant afford it.

$400 for a driveshaft?!?!?!?!?!?! Does that come with KY too? :headpop:

I paid $250 for mine and was local. Even Tom Wood should be cheaper than that. For $525 you get the SYE ket and heavy duty shaft.

They are not that hard to put in. A good set of snap ring pliers and a torque wrench going to about 210 ft-pounds should be the special stuff you need for installation.

[jeepik]

well for a 3 inch lift you dont need an SYE

but i think your problem is deeper then that


are your shims on right??? is your tcase alright?? you said the chain was slipping...and it shouldnt be. under any circumstances...cuz if it is slipping some gear has lost some teeth in the tcase

[91 Green YJ]

-=- originally posted by jeepik -=-
well for a 3 inch lift you dont need an SYE

but i think your problem is deeper then that


are your shims on right??? is your tcase alright?? you said the chain was slipping...and it shouldnt be. under any circumstances...cuz if it is slipping some gear has lost some teeth in the tcase

Well it isnt slipping anymore. it has been fixed since. The New Jersey drive happened several months ago. then it was with my mechanic for about three months when i was in San Diego for the summer. He fixed the t-case.

Yes the shims are on right. they were attached to the leaf springs when i got them from rough country. I just slapped a new u-joint in and put the driveshaft back in. i bought 2 u-joints, both with one year warranties, this way when the next one goes, i can slap in my spare while i get the blown one replaced for free. This should carry me until i can afford a CV shaft and SYE. Anyway, the dirveshaft angle actually doesnt look too bad. I'll take pics later and post em so you guys can see it and tell me what you all think.

[NE-RokToy]

you say the shims are in right, but which way is the fat end of the shim facing? It should be facing the front of the jeep. A TC drop would probably solve the problem until you can buy a hack and tap SYE and get a XJ front shaft cut down. good luck

[91 Green YJ]

-=- originally posted by NE-RokToy -=-
you say the shims are in right, but which way is the fat end of the shim facing? It should be facing the front of the jeep. A TC drop would probably solve the problem until you can buy a hack and tap SYE and get a XJ front shaft cut down. good luck

Shims are facing that direction. and i already have a tcase drop on it.

Whats involved with doing the XJ shaft? I think i could get ahold of one pretty cheap and easy. then all i need is the SYE which i know i can get for 210

[NE-RokToy]

Also are you still using the same yoke on the axle? I would imagine it is not in original condition after all this carnage and could be leading to accelerated wear and eventual breakage.

[91 Green YJ]

-=- originally posted by NE-RokToy -=-
Also are you still using the same yoke on the axle? I would imagine it is not in original condition after all this carnage and could be leading to accelerated wear and eventual breakage.

See thats another part of the problem here. My rear axle is NOT original!!! It has ABS brake sensors in the drums with the wires cut off. 92 Wranglers didnt have ABS!

[jeepik]

point i was trying to make is if the angles are right, and you say they are..the u-joint should have a healthy life.

you are breaking all these u-joints cuz something is out of wack

check the pinion bearing if there is any movement

and just becuase it was a the shop doesnt really mean the t-case is fully fixed

something isnt right here, u shouldnt be breaking u-joints if you have no vibes

[91 Green YJ]

-=- originally posted by jeepik -=-

something isnt right here, u shouldnt be breaking u-joints if you have no vibes

I dont have vibes until the ujoint blows. then i got tons of em

Yeah something is definitly wrong though. I have a feeling its the rear yoke. The U-joint made for my axle is just a touch too small for the yoke. (to short end to end) and it slides a little back and forth in the yoke.

[mckeddie]

i had the same prob with mine. ended up being the yoke was worn. i would replace it if i were you, as stated above. you probably wore a spot in it when one of the joints let loose. i just replaced my ujoints every 2 weeks till i got my 9" built.

greg

[ddewar53]

Just a thought - I replaced the D35 in my '90 with one out of a '95 - had to change DS because
(a) the u-joint for the '90 was smaller and
(b) the DS for the '90 was longer

Looks like the best option is to go with SYE.

[JTucker]

Is the u-joint always breaking at the yoke? If so I would try another yoke for now if you cant get a sye put in. If the joint feels a little loose it is because the ears are egged out a little, letting the caps spin and burning up the u-joint.