Build Thread 1986 CJ7 Build

[KRUPP]

Ha! Nah on the 4:1 gears. It did cross my mind though.
Do you have any popping out of gear issues with yours?

 

[Belizean]

Did that couple years ago and went up to N Carolina this last late April early May and we did some different trails and back roads. Popped out once and I didn’t know what happened at first. Thought maybe it did something to the dive shaft or something else happened. Nope got back in and shifted back in. I did use the heavy springs ball kit. Who knows

 

[KRUPP]

Jan 16, 24:
-While I wait for the temps to rise and the Transfer Case seal/gasket kit to arrive, I’ve been considering drilling and tapping the bottom of my differentials and installing a low-profile drain plug. I think there used to be one there back in the early years of the Dana 44 . There’s a boss/thickened pad cast in the bottom of the diff, in both the IH rear and the Jeep front. I already have a 3/8” npt tap. I’d just need a couple, short, female, allen bit plugs. Maybe with a magnet too. If I installed them flush to the housing, they’d be pretty safe and rocks wouldn’t hang on them. It appears there’s clearance from the ring gear too on the inside.
Someone has got to have done this?

 

[CJ]

Good observation. I've put 3/8 npt plugs in there before. Be very careful when you tap and check the fit often while tapping so the hole doesn't get too big and you end up with a bad fit or the plug sets to deep.

 

[Armyvet25]

Also, drilling close to to the end of the casting makes for a weak spot to crack if ever hit on a rock when crawling

 

[KRUPP]

Thanks fellas. I’ve sourced a couple low profile socket plugs, with magnet, and plan to do it this evening. Finally above freezing here too.
A bit of research says Dana did have a drain there, up to about 1970+\_
Maybe someone with an early CJ (pre ‘76) with Dana 44 could verify?

 

[CJ]

My 72 CJ5 w/ factory LS Dana 44 does not have a drain.

 

[KRUPP]

I did a bit more research and it looks like the older Jeep and Willys D44s ('41-'71) had a drain plug. Had em in all their axles offerings.

 

[Belizean]

That would have been a nice added feature on the 20 axel also. But nooooooo. Don’t see any place to add it anyway after the fact.

 

[KRUPP]

Jan 17, 24:
-Got a lot done this afternoon, since it’s above freezing today. Worked to about noon, worked out, ate lunch, then had the whole afternoon for the Jeep. About 45 and sunny - opened the garage door and it was really nice.
-Installed the drain plug in the new front housing. Took my time and was fairly straightforward.
-Removed the rear end diff cover in prep for doing that drain plug install as well. Oil looked surprisingly bad, for being only 9 mo. old. Hmmm?
-Removed the Transfer Case . Lotsa nasty, oil-caked, red sand to deal with. PO musta driven same red dirt road a lot. Cleaned/wire brushed it in prep of partial disassembly.
-Nice enough to take the front housing outside and spray a coat of primer on it.
-While I wait for the shift rod springs and seal/gasket kit, the plan is to install the rear drain plug. Maybe tomorrow evening.

 

[KRUPP]

Jan 20, 24:
-A nice day today. About 45 and sunny, so, open garage doors. Ahhh!!!
-Began the partial disassembly of my Dana 300 Transfer Case . Fairly simple case.



-On a hunch, I only bought new Yokes and a seal/gasket kit. Today, I’m happy to find that all bearings are fine, but yokes have bad seal grooves. Perfect!
-New yokes from Crown had too large of shrouds, which is common. Changed them out, carefully, with the originals.

 

[CJ]

Nice, just don't seat the seal (use a spacer), different groove.

 

[KRUPP]

CJ: which seal are you referring to?

 

[CJ]

CJ: which seal are you referring to?

You had a worn groove, just space it out a quarter (,250) inch and you can save all your parts.
I'm so old school that I fix not replace everything.

 

[KRUPP]

Trimmed the skid plate/cross plate where the front driveshaft intersects.
Noticed that my shaft was rubbing at the edge of the plate, when the axle articulated.
Cut out a notch. Will see how it goes with the new driveshaft though. Plan on a new one with the new Dana 44 front.

 

[CJ]

Had a nice talk with K.
We came up with something...
One year ad free here,,,,
Jeopardy type annswer, 'What is a case spreader?

 

[WHATROAD]

Removed the T-case. Lotsa nasty, oil-caked, red sand to deal with

Not sure how well you cleaned the under carriage after your trip to Utah, sounds like it could be Moab red. I'm still finding it under mine nine months later

 

[CJ]

Not sure how well you cleaned the under carriage after your trip to Utah, sounds like it could be Moab red. I'm still finding it under mine nine months later

Red for me ips GA clay ..Nasty

 

[KRUPP]

Ooooh! I know. I know the answer


I have a trivia question for you, CJ.

I mentioned that my grandfather worked for Stinson Aircraft in Detroit back in the 20s - 40s. Here he is…


With your aviation background, maybe you could help identify the item my grandpa is pointing to in the pic below? I believe he helped develop whatever it is & have wondered for years.

 

[Belizean]

Wondering if that’s the backside.