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If you read this Moses, many thanks for your Dana 30 rebuild article, it's the only one I've found that helped me. Here is my problem in a rather large nutshell. 1995 YJ, 2.5 5spd. I had an axle seal leaking and bad lower ball joints so I figured it would be a great time to upgrade to 4:88 gears and 4340 axles since I am rolling 33-12.50's. I opened up the diff to find a recent but very poorly installed 4:56. The caps were on upside down and it had about .100" backlash so I am essentially starting from zero. The carrier bearings appear to be original so I am fairly sure the shims are close but I am making a set of test bearings for all positions. There were no shims behind the forward pinion race and only the slinger behind the bearing, probably the culprit of the massive backlash. The pre-load shims are another issue. It appears the installer used all the shims he had and all that were on it originally. The original shims (determined by some discoloration) stacked to .057", He or she added another .041" to stack out at .098". I can do all the setup and the new gears have the pinion depth marked so I know what to shoot for, my question is what ballpark the pre-load shim pack should be in to start the setup? If I read correctly, the torque for the pinion nut is 160-200 ft/lbs so I know if it gets too tight before I hit 160 there are too many shims and if it hits 200 and doesn't have enough pre-load, not enough shims. I would just like a good spot to start. I am using a Motive gear set if that makes any difference. Thanks in advance to whomever might be able to help. I'm sure the Dana 35 in the back is in similar condition so any help will be greatly appreciated. I would also like to mention how awesome it is to find a forum that is just simple and to the point without all the smells and bells to stagger my poor old Dell to a standstill!
Moses, I am pressing forward with the reverse engineering and documentation of my 85 CJ7. I have run into a snag and hope you can shed some light. The front axle has been upgraded to a dana 44. The wheel base appears to be the stock wide track CJ of 56" WMS to WMS. Both Inner axles appear to be custom length (28 7/8" and 15 1/2") 30 spline. Now for the question. The outer axles do not appear to be customized and at first appearance seem to be "CJ" (8.72" 27 Spline) CJ spindle, 6 bolt locking hubs, 6 bolt brake caliper and rotor, and etc, however the outer axles have the larger 1.188" cup size yoke. (5-760X u-joint). Can you identify what vehicle class these outer axles are native too? Through my research, I found a few axles with the larger cup yokes and 27 splines, but I have been unable to positively identify one with the correct length. They are either too long or in most cases do not publish a length. The yoke casting markings are "Spicer", "F36616", and "M5 L866". Google does not hit on these numbers. Any insight you may have will be appreciated. William