How to: Vacuum Disco Elimination, Axle Tube Sleeve Fix, ubolt Eliminator - 56K beware
Last year while wheelin’ in Colorado with some friends, I developed a serious crack underneath my passenger side SOA perch. The problem didn’t surface till the next day while I was in Moab doing a relatively easy trail. All the sudden my front axle started making some interesting noises, and looked as if I had balljoint issues at first glance. So Randy (Rock_Worm) and I got out to take a look. Next thing I know, Randy say’s something to the effect – hey Joe, I think I’ve found the problem”.
Anyway, we did a trail repair & then towed it back to our campsite in Moab. The following day, Randy, Larry & I welded it back up as a temporary fix so that we could continue wheelin’ for the next week. It has held up fine ever since & has several other trail runs on it – but I wanted a more permanent fix. So, this is where my “Disco Elimination & Axle Tube Sleeve Fix and ubolt eliminator” begins.
Here’s what the initial crack looked like:
Face of the axle tube:
View from underneath:
View from the back:
So, back at my campsite, I borrowed a friend of mine’s Lincoln MIG welder and we cleaned up the crack and welded it back as best we could.
My friend Larry, from WA, helping do some welding:
Beginnings of the repair:
Okay, now that I’ve explained how my troubles started – here’s what I’ve done as a more permanent fix. Yea, it’s a HPD30 and some may say; “why polish it?” This fix cost me a grand total of ~$30.00 for the 3”x.250” DOM, including hardware. I already had everything else laying around my garage.
I had a pair of perches, so I got some 3”x.250” DOM and started doing some measuring.
I secured the Jeep on jack stands & pulled my tire, then started to remove the Warn hubs:
Then I removed the Warn spindle & Vanco calipers and rotor:
just curios as to why you attribute the break to the disco cast iron mount when the break occurred on the tube, and not at the mount?
He who hunts in a pack is still a dog. The lion hunts alone, and so do I. - Napoleon
Conducting an argument by appealing to authority is not using your intelligence; it is just using your memory. - Leonardo Da Vinci
I'm not sure what I may have said to give you that impression. Could you point me to where I indicated or implied that? Thanks.
By completely removing the vacuum disco housing (which I have not needed ever since I installed the Warn hub kit and 1 piece Warn inner ~5-6 years ago) it sure makes it far easier to sleeve the axle tube with it completely gone.
IIRC, the sleeve ended up being ~21.25" in length, and since I left a few inches of the original tube at the inner C and differential, this made for sleeving it fairly easy.
Are you using grade 5 hardware for your u-bolt eliminator? I am looking into helping a buddy with his dana 30 and as it is trussed along the bottom, there is no room for u-bolts(making room could prove to be very labor intensive). Upon looking into it I have heard there are some issues with the hardware stretching/loosening. A google search for "ubolt eliminator" brought up this thread so thought I would get your thoughts/experiences. What size hardware are you using?