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Unread 09-15-2011, 07:51 PM   #1
YJSos
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Questions about putting TJ axles in my YJ D30

I am rebuilding my Dana 30 which has the vacuum disconnect. I got a d30 from a 97 TJ which has the one piece passenger side shaft. I bought a kit from Complete Offroad which contains 2 seals and a block off plate: http://completeoffroad.com/i-123369-yj-disconnect-block-off-kit-w39147-kit.html
I read the how to on STU's web site (http://www.stu-offroad.com/axle/yjd30convert/yjconvert-1.htm)

My Questions are:
Which seal goes where? I got 3 in the kit, maybe 2 go together?

In the pics on Stu's site it shows one seal by the pumpkin and one out by the outer edge of the disconnect area. Do I need to fill that area with gear oil also since its going to be 2 seals there?

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Unread 09-15-2011, 09:23 PM   #2
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You can figure out which one goes out by the CAD, but it'll just get worn away because the shafts aren't machined there. I only put one at the pumpkin, I don't know which of the three you have. If you do a search by part number on Napa's website for part number 11800 you should be able to get sizes so you can match the seal. No need to add any fluid except in the pumpkin.
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Unread 09-15-2011, 09:36 PM   #3
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Its pretty obvious what goes where when you take the axle apart. In the picture on the website the one on the left goes drivers side at the pumpkin. It Wouldn't fit passenger side if you wanted. With the other 2 find the one that fits in the driver side by the pumpkin. Press it in and don't even bother putting on the one by the disconnect.

Don't put fluid in the disconnect either. You'll only need the carrier lubed now.

I just finished up this exact swap yesterday. Bought both seals locally and made my own block off place.

-chris
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Unread 09-16-2011, 02:32 PM   #4
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Thanks!! I appreciate the help.
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Unread 09-17-2011, 08:32 AM   #5
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Any suggestions on pressing the inner seal in? I fought it for a while last night and got nowhere.
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Unread 09-17-2011, 10:38 AM   #6
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I used a stick of 3/4" all thread(doesn't have to be threaded, just what I had) I put it through the axle tube on the opposite side, then I found a socket that fits perfect on the seal without messing it up. I held the socket while I made sure the seal went it straight then I had someone tap(hammer w/ a mallet) the rod to seat it all the way...

-chris
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Unread 09-17-2011, 10:45 AM   #7
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I used threaded rod with large washers that fit the seal nicely. Put some nuts on it that'll push the washers/seals as you tighten the nut. Assuming you're talking about the seal in the pumpkin? I used a couple different sized washers to step it up and allow the nut to push.
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Unread 09-17-2011, 10:51 AM   #8
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I pulled the carrier and tapped it in place with a hammer and big *** socket (1 3/8's I think)
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Unread 09-17-2011, 11:52 AM   #9
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Quote:
Originally Posted by timatoe View Post
I pulled the carrier and tapped it in place with a hammer and big *** socket (1 3/8's I think)
This is what worked for me, just make sure the seal goes in evenly.

That kid looks like it comes with 3 seals, the two that are similar are for the differential, if its only the one seal, then the smaller of the two goes in the differential.
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Unread 09-17-2011, 02:42 PM   #10
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For help installing passenger-side diff seal when going to one-piece shafts:
-Use the threaded rod and washer technique, or
-Get 1 or 2, 1" long extensions and a socket that fits around the edge of the seal perfectly, then go in from the driver's-side short tube, through the center of the diff, and rubber mallet the seal in using extensions and a very large socket. I found this option to be the easiest, it is even easier if you have someone with their hand inside the diff housing hoding the socket to the seal while someone beats on the end of the extensions (lightly).

Suggestion for maintenance on that passenger-side diff seal:

I recomend purchasing the alloy-usa front axle housing seals. They have them for sell at quadratec and other companies may make them for cheaper. Basically google "alloy usa axle shaft seal". These seals will lock water, dirt, mud, sand, small mamals, etc out of your axle tubes (no one likes small mamals in their tubes). This will prevent premature failure of that inner axle seal. As you will soon find out, that seal is a royal pain in the A** to install, and you don't want to be doing it all over again once your axle tubes fill with sand.

I highly recomend those lockout seals if your heep ever sees mud, sand, or water.
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