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My $120 CJ7 build

Discussion in 'Jeep CJ Builds' started by daddyusmaximus, Aug 25, 2017.

  1. Nov 16, 2019 at 2:24 PM
    #141
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    Well, nothing has got done on the Jeep all summer. Money is always tight during the summer because my wife is a teacher's aid, so no paycheck. Also my shoulder is NOT healing from the surgery I had back in the spring... I have just started my third round of physical rehab with it. The VA keeps telling me the surgery went well, and that it's useless to even get a new MRI for 1 year, because it will just show abnormal anyway... They say it's inflammation from the surgery. I've had 2 previous shoulder surgeries... they healed much quicker.
    Anyhow, I'm getting pissed sitting around, so I decided to start in on the axles. Well, first I took out the fuel tank. No photos, but I don't like how close the pumpkin is to it with the YJ springs, so I'm gonna get a 2" tunnel put in the front edge of it kinda like a transmission tunnel, to give it some room.
    First thing was to get one of the axles out. I decided to do the front one first. I lifted up the frame with the engine hoist,then worked the axle out from under, and onto a set of rollers.
    [​IMG]
    [​IMG]
    I have too much crap in the garage, so I decided to use the Jeep itself as the workbench for the axles... I rolled it around to the rear, then hoisted it over the rear frame rails. Using double layers of plywood, I set it on jack stands on the tail of the frame, and strapped it down.
    [​IMG]
    [​IMG]
    [​IMG]
    I set to work soaking every nut I could find with PB Blaster, and started in on one side. Being as my shoulder isn't up to snuff, and I haven't been able to stand long periods for years, I didn't get far, but I did make progress, so I'm good with that. I got one side brake caliper off, one Dodge truck automatic hub out, and that's where I got stuck. I stared in on the cotter pins, but the first one I came to was a PITA, and I decided to let it soak,and just call it a day. Just for fun, I tried the other side... pin came right out...
    [​IMG]
    [​IMG]
    [​IMG]
     
    JKBob 25, chris4x4 and aggrex like this.
  2. Dec 14, 2019 at 12:27 PM
    #142
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    Well, the trend of nothing going right is still active. I couldn't get the front axle apart, so I ended up taking them to a friend's house. I neglected to get photos, but same ole stuff. Used the cherry picker to lift them, backed the trailer into the garage, (that took a dozen tries) and took both the "good" one and the original to his place. He works as a mechanic by trade, so he can use the shop at work after hrs. Hopefully he can heat them up, and knock them out from behind with an air hammer.
    Today, I decided to give the rear axle a try. It laughed at me... Broke a bolt off in the caliper bracket for the left side. Then I discovered what was inside...
    [​IMG]
    [​IMG]
    Holy crap, I was driving this in the green CJ5 up till I tore it down to build this CJ7.
    Now, I do remember the green Jeep having a vibration in the rear when I was driving it. I figured it was the pinion bearing not getting enough oil due to how far the housing was rotated. I think I was right about that. It won't allow the carrier to rotate so I can get to the cross pin, or "c" clips... If you grab a rotor, you can twist the axles,and see the carrier try to move, but the pinion is frozen.
    Can't even budge it with my tanker bar.
    [​IMG]
    Any ideas here? Or will I end up letting Ryan take this one apart too...
    By the way... notice the nice repair job on the yoke... 3 bolts one size, 1 another. I'll change that out anyway as I'd rather have the u-bolt type than the strap type.
    [​IMG]
    How the hell do you get an axle apart when you can't rotate the carrier?
     
    JKBob 25 and chris4x4 like this.
  3. Dec 14, 2019 at 12:48 PM
    #143
    Jim Beam

    Jim Beam Well-Known Member

    Joined:
    Feb 11, 2019
    Member:
    #2891
    Messages:
    348
    Gender:
    Male
    First Name:
    Donald
    Vehicle:
    1986 CJ7
    Fuel Injection, Dana 44s, T18, 4.10s w/lockers
    When I installed the u-bolt setup on my CJ rear diff it was assembled with the tires on the ground and the pinion nut came right off. You could try bracing the brake rotors at the wheel bolts with that big long bar.
     
  4. Dec 14, 2019 at 2:32 PM
    #144
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    Not trying to get the pinion nut off. Have to get the carrier and axles out first, but I can't because, use the pinion won't rotate. Can't get to the cross pin in the diff, or the C clips. Unless I'm missing something, the axles have to come out first...
     
  5. Dec 14, 2019 at 4:14 PM
    #145
    Jim Beam

    Jim Beam Well-Known Member

    Joined:
    Feb 11, 2019
    Member:
    #2891
    Messages:
    348
    Gender:
    Male
    First Name:
    Donald
    Vehicle:
    1986 CJ7
    Fuel Injection, Dana 44s, T18, 4.10s w/lockers
    That looks like a Dana 44 with the 19 spline axles. As I recall, the 4 bolts on each end have to come out to pull the axles, which by now might require an axle puller. Just to make sure the axles stay in, I put in an extra bolt on each side on the bottom so there would be 5 bolts holding the axles in. From there the bearing caps have to come out to remove the carrier of course. On my CJ I have converted to full floating axles which changes a few things back there.
     
  6. Dec 14, 2019 at 9:36 PM
    #146
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    The front axle is a Dana 44, and probably has the 19 spline axles. The rear is a Chrysler 9.25. That's the one I was working on today.
     
    JKBob 25 and chris4x4 like this.
  7. Dec 15, 2019 at 1:47 PM
    #147
    Jim Beam

    Jim Beam Well-Known Member

    Joined:
    Feb 11, 2019
    Member:
    #2891
    Messages:
    348
    Gender:
    Male
    First Name:
    Donald
    Vehicle:
    1986 CJ7
    Fuel Injection, Dana 44s, T18, 4.10s w/lockers
    Yup, agreed, my bad. So just how is that pinion frozen?
     
  8. Dec 15, 2019 at 5:20 PM
    #148
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    It had a vibration in it when I was driving it. I think the guy that built the CJ5 it came out of had the pumpkin rotated up too far, and it didn't get enough oil.
     
  9. Dec 16, 2019 at 8:01 AM
    #149
    Jim Beam

    Jim Beam Well-Known Member

    Joined:
    Feb 11, 2019
    Member:
    #2891
    Messages:
    348
    Gender:
    Male
    First Name:
    Donald
    Vehicle:
    1986 CJ7
    Fuel Injection, Dana 44s, T18, 4.10s w/lockers
    JKBob 25 likes this.
  10. Dec 17, 2019 at 12:52 PM
    #150
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    The good news is the pinion now turns. The bad news is, it doesn't matter...
    I took off the yoke, put back on the nut, and gave the pinion couple good raps. After that I could turn the diff no problem. I got the crosspin bolt out, and started to remove the pin. Bang, all progress once again came to a screeching halt. The ring gear is so fat, it's in front of the crosspin. The pin only came out a bit,and smacked into the teeth of the ring gear, leaving me to wonder hoe the hell they put it together...
    [​IMG]
    I looked inside, and sure enough, without getting the pin out, I don't see how I can get the "c" clips out to remove the axles...
    [​IMG]
    Really starting to hate these axles...
     
    JKBob 25 likes this.
  11. Dec 17, 2019 at 2:39 PM
    #151
    Jim Beam

    Jim Beam Well-Known Member

    Joined:
    Feb 11, 2019
    Member:
    #2891
    Messages:
    348
    Gender:
    Male
    First Name:
    Donald
    Vehicle:
    1986 CJ7
    Fuel Injection, Dana 44s, T18, 4.10s w/lockers
  12. Dec 17, 2019 at 10:58 PM
    #152
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
  13. Mar 24, 2020 at 9:23 PM
    #153
    daddyusmaximus

    daddyusmaximus [OP] Well-Known Member

    Joined:
    Nov 2, 2016
    Member:
    #446
    Messages:
    185
    Gender:
    Male
    Vehicle:
    '79 CJ5
    360, D44 front, Chrysler 8.25 rear, 4 wheel discs, rear Detroit locker
    After another long break of nothing getting done, Jeep money going to other things, (OK one was a project gun) and a bunch of crap going wrong (including all this virus crap) I'm back at it. I'm halfway through another round of physical therapy on the shoulder, and it's going much better. Should be after almost a year...
    Problem I had getting the front axle apart was I couldn't get the spindles off the knuckles. Took the old housing, and the replacement junkyard one to a friend from my off road club, who is a mechanic by trade. He was able to use a torch to heat it, then knock them out from behind with an air hammer in the shop after hrs. Of course, it took me forever to get back up there to pick them up once he did...
    [​IMG]
    So, I get all the parts home, and now I have the remains of almost two complete units to go through.
    [​IMG]
    I won't be using the 4.88 gears, of the originals, but the 3.55s of the junkyards unit are in fine shape. This will also get me a comfy 1,925 RPM @55mph and 2,450 @ 70mph when cruising down the road on my 35s... Before, it had 33s, and 4.88s, and would turn over 3K doing around 55 or 60mph. I started looking up all the seals, bearings and goodies I'll need to rebuild it, but with typical off-roader enthusiasm... first thing I ordered was an Eaton Trutrac... lol.
    Here you can see the splines on the outter that blew when the axles was still in the old CJ5, next to the nicer axle from the replacement junkyard unit. It looks to be not boogered up too awful bad, and could still serve as a spare, so It will be cleaned up and taken along with...
    [​IMG]
     
    JKBob 25 and aggrex like this.

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