Here's the situation if you haven't read up to here. I broke an axle shaft in my ford 8.8 and like most c-clip shafts the piece in the diff wouldn't slide in to remove the c clip. The splines no longer lined up so the normal way of c clip removal wasn't an option.
I pulled both shafts and the Detroit out to find the shims on the driver side completely thrashed and no longer in place. And got a better look at the piece still lodged in the Detroit. After a bit of thinking I came up with a plan.
I measured the diameter of the c clip groove in the passenger axle shaft to find it is 13/16". I them disassembled the Detroit to get to the side gear. CAUTION DETROIT LOCKERS ARE UNDER GREAT PRESSURE FROM INTERNAL SPRINGS REMOVE THE CASE HALF SLOWLY AND EVENLY. Once apart I took the side gear with the stuck piece and clamped it into a vise using some thick leather to protect the splines in the side gear.
Using a Milwaukee 13/16" hole hawg bit with the spring loaded centering pin. I drilled right into the end of the axle that retained the c clip. The center of the axle is drilled making the perfect center punch for drilling the hole. I got to the depth of the c clip groove and the the c clip retainer popped right off and the axle piece fell out.
This is not really a trail fix but a fully charged cordless drill and a vise could do this job. I used a magnetic drill press at work. I also used a new bit so it cut through it in about 20 seconds max.
Damn, can't believe I overlooked this build! Nice work so far on the continuation. And that K2 place looks sick!
K2 is good but it's only a marginal substitute for the original K-Rocks. But it was shut down because of an inheritance of the land it was on and heir wanted it for only his family to use. It was leased land. So the folks that ran it found new land in the area and opened K2. It's the closest GOOD wheeling there is to me. I live in the flat spot in between Dallas and El Paso and I'm not big on sand dunes. The other pics are from las cruces and that's only about 5-5.5 hours away. I have lots more planned for this little jeep hopefully it will turn out like I want it to.
Install super 88 kit: waiting on shipping
Reinstall Detroit: waiting on super 88 kit
Misc axle rebuild parts: waiting on previous stuff
Replace driver unit bearing: diagnosed and need to buy parts
Main skid repair and raise: not started
Add brace to engine skid: not started
Replace TREs: parts here and waiting
Install PSC steering box: not started
Full weld front and rear fenders: less than half way through tons of welding and grinding
Additions to the roll cage: I have the pipe and bender just need the time.
Rear seat location for better leg rom for the kids: still thinking and measuring waiting for the ah ha moment.
Anyone know the minimum back spacing you can run with 35" tires on a TJ. My rear axle will be 1" wider than factory tj specs. I want to run 5.5" bs wheels. I'm wondering if I can get away with it without wheel spacers or maybe use some 3/8"-1/2" shims or something. I can CNC plasma cut them to hub centric and just make sure the studs are long enough to have good thread engagement. I know I can order up a set of spacers but if I could make it work for free that would be great!
I ran 4.5 backspace 15x8 wheels with 35x12.5 and it worked plenty fine. 5.5 will be close, but worth trying with the slightly wider axle. Up front was where mine rubbed, while turning with 4.5" backspacing. Also, if you're talking about the Canyons, are they 15x8 or 15x7?
Like others that have posted, I'm a huge fan of your fenders. Any details or links on those? Thanks
Well here are the updates. Superior is giving the run around on the super 88 kit. I've had them ordered for 5 weeks and they are saying it'll be another 5 before they get them out. So I found some stocker axles from a fellow member and hope to get those in soon. The other development is instead of blowing that money on the super 88 kit I'm thinking of building a Dana 60. The build would be a semi float, 5x4.5 lug pattern with 35 spline shafts. The cool part is I think I can reuse the brake setup from my 8.8 and retain the e brake and disc setup. I think I can do it for $1000 or less. I will update with for sure answers on the specifics.
So far I've got my D60 housing in the works cutting off old brackets and a truss. And bought a set of axles with bearings, mount plates, brake mounts and are drilled for both patterns. Next I'm ordering the housing ends.
Got rear end put back together this weekend. Needs gear oil and brakes bled. I'm ordering a new top and door uppers soon and I'm thinking bestop trek top. Any opinions? Also I found the factory paint color in spray cans so I can get fenders repainted after I finish them.