front axle unit

[Big_Al]

Appears my front axle 4WD unit is leaking out of the rear seal from the drive shaft all under my jeepster...in an effort as most of you know to rebuild this thing, I keep chasing one prob after another. I am due my manuals in the next few weeks, and I hope I can be a little more independent, but until then I hope to keep picking your brains. Can I disconnect the front axle (remove the drive shaft) while I am fixing it and still use the jeepster in 2wd. Will I need to take it off to fix the leak anyway??? The front of the case is bone dry so doesn't seem to be the gasket. Haven't used it much other than to try it out and see if it works in 4WD and it does. Seems pretty full, has not leaked enormously, just enough to make a mess. Are parts easy to find. (seal or bearing)??? Any ideas experts??? [img]images/graemlins/spank.gif[/img]

I don't think you can drive in 2wd with out the Tcase. If it is a dana 20, 4wheel parts has all the rebuild stuff for it. Dana 20 stuff is easy to find (or should be) if they don't have it. Good luck and let me know because mine is leaking too... [img]images/graemlins/chair.gif[/img]

[GRQster]

Al,
All of your power goes through the transfer case. You can't remove it and drive the Jeepster.
It's seal that has gone bad and will need to be replaced. Don't let it run dry.

[Hurcules]

I can't tell if you are talking about the transfer case or the front axle it's self. If it is the transfer case that is a real easy fix for the rear output leak. Take off the drive shaft, take off the nut in the middle of the yoke, take out the yoke and replace the seal. Then put it back together. If you have no clue on how to do it it should take you about half an hour. If it is leaking betwwen the tranny and t-case, you need to take out the t-case. Again, this is pretty easy, take out both driveshafts, there are 4-5 bolts holding the t-case on, take out the tunnel cover ont he floor board, disconnect the shifter, then slide the t-case off and out. I have found ultra black RVT silicone works fine on this sealing surface without a paper gasket. The case gets filled up with that great smelling 80w-90 gear oil. [img]images/graemlins/puke.gif[/img] I recently did this myself and it took under an hour. The t-case does not need a jack, it is only about 50 lbs.

If it is the axle it's self that is another similar issue, but not as easy. You need to replace the pinion seal. The nut on this one is tourqed higher and may be a real PITA to get off without an impact wrench. There is also a crush sleeve in there that you may or may not have to replace. I would not attempt that repair unless you are are with someone that can run a test pattern on the gears to make shure all the gears are still meshing right. The front axle is free floating, as long as the hubs are unlocked and the transfer case is not in 4x4, you don't even need oil in it. (Nothing spins)

[Big_Al]

You have the first part right...sorry about the confusion. The yoke, should I go ahead and replace seals on both ends. Is there one on the other end. That's the hard one, right. In other words, not knowing how this thing is put together, I am having a hard time trying to put together the repair. Where is the case labeled as to what type it is so I can get the seals? Couldn't find any markings. Thanks for responding. Big Al

[Hurcules]

The t-case is a Dana 20. The one on the front of the case is the same deal as the one on the rear. Rosser Jeep www.thejeep.com or someother Jeep place will get you the right parts without any parts store hassles.

[badbrad]

Al,

The transfer case is a Dana Model 20. Do you need a picture of the exploded parts diagram? I can scan and post here like a picture, but do not have a web site.

Brad

[badbrad]

OK, there are four pages from the parts manual. Two views, A & B, with parts list for parts shown on each view.

Hope this helps.

Brad.

[badbrad]

Part numbers & descriptions for view A.
Brad.

[badbrad]

View B. Rear Output shaft, etc.

Brad.