2005-06 Jeep OPDA_CPS_Distributor Failure - Page 38 - JeepForum.com

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post #556 of 5449 Old 02-09-2011, 03:45 PM
Zeep
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Quote:
Originally Posted by 2006_Sport View Post
Im pretty sure they sell a complete replacement OPDA too, it's a "high volume" one apparently.



Edit: they used to at least. I remember seeing it on their site a while back, it's not there anymore.
I believe that " high volume " is their oil pump replacement.


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post #557 of 5449 Old 02-09-2011, 05:43 PM
usjeepers
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Quote:
Originally Posted by willydigger View Post
Dodge-wholesale.com reply:

My inquiry:

...I was curious if you know the reason for the price increase on the 2005 distributor. Is there a new supplier or change in the product? The Jeep community is pretty nervous considering that during the last back order there was no increase. Also I assume you will honor the price paid prior to the increase for orders already placed (like mine). Please let me know what you know.

Dodge-wholesale:
That sucks, but I'll have to pay the $250 and hope it isn't the same pos that they have been selling us and installing in out 05 & 06s so far.

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post #558 of 5449 Old 02-09-2011, 07:59 PM
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[QUOTE=TheFog;10943576]I highly recommend greasing it with it in the vehicle with the engine running. I made a post about this a couple of pages back, the grease when pushed in with the OPDA not spinning at a decent rate causes it to just lube the bottom part of the OPDA and spill into cavity between the top and bottom bushing.

I'll try from the bottom as suggested but son-of-a-gun it's a bear to get to...
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post #559 of 5449 Old 02-10-2011, 06:51 AM
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It's -24 this morning, I was scared to start the jeep, figured it'd squeal like a pig again......nope.
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post #560 of 5449 Old 02-10-2011, 03:52 PM
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wow, it was -2 when i left work last night and i thought that was cold enough. I pulled mine out after a few days of driving it and everything still looked like it did when i first did the fogmod. Ill start taking it out and taking it apart every oil change or every other oil change to see how the valvoline palladium grease does.
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post #561 of 5449 Old 02-10-2011, 07:07 PM
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I started on some modifications on my unit today. This is basically to change the lower section of my 06 unit to be like the older 04 unit.

Here's what the 06 unit looks like with the lower bushing removed. Man, those 3 channels are quite big. They travel up and come out right above the top of the bushing. One thing though, they were bone dry, and my unit has 60k miles.


Here is a shot comparing the 04 and 06 lower bushings. The 06 is about a quarter inch longer


The lower bushing was wasted. And the wear was very uneven. On the bottom where it meets the gear, it was out two and a half thousandths and eggshaped. On the top, the wear was a little less-it was out about a thousandth.


On the shaft, on the area where it meets the bottom bushing, the scoring went in about a thousandth and a half. At the top bushing area, the scoring barely went in-about half a thousandth. Here is a shot of the shaft repaired, all welded up and polished. Just like new. This is the same shaft as the one from the bottom picture (the shaft without the groove)





Here's the weird part. The top bushing in the unit was ok. We mic'd the bushing top, middle, and bottom, and it looked good. So I'm going to re-use it.

This weekend, we're going to cut the flat spot and drill the hole in the unit lower. We also need to fab up a new lower bushing which will be the same length as the 04 bushing. The one thing that I will change from the 04 design is that I will groove the lower bushing instead of grooving the shaft. The machinist thinks that this is the better move, and should be more efficient.

I'll post more pics as I finish up.
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post #562 of 5449 Old 02-10-2011, 07:59 PM
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Interested to see the results of this, thanks for posting.

One question, how did you remove the bushings? I tried removing them on an old distributor I have but didn't want to tear the whole thing up so I gave up. They must be pressed in there really good
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post #563 of 5449 Old 02-10-2011, 08:18 PM
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Quote:
Originally Posted by lope View Post
Interested to see the results of this, thanks for posting.

One question, how did you remove the bushings? I tried removing them on an old distributor I have but didn't want to tear the whole thing up so I gave up. They must be pressed in there really good
If you want to save the bushing, you gotta use special tools or else you'll destroy it. The machinist used this gizmo that screws in and then you extract it like a slide hammer puller. If you don't need to save it, you can tap it out with a punch.

He also explained to me that when it comes time to install, he'll freeze the bushing with liquid nitrogen to shrink it, and then use another type of tool to tap it in.
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post #564 of 5449 Old 02-11-2011, 07:26 AM
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Quote:
Originally Posted by tkki1230 View Post
This weekend, we're going to cut the flat spot and drill the hole in the unit lower.
Very interested to hear how this turns out.

In thinking about that hole you'll put above the lower bushing, it looks to me that the flat spot that you're going to grind in is absolutely necessary. From the picture of cam and OPDA in the engine that is posted on page 1 of this thread it looks like that part of the OPDA is covered by the block, and without the flat spot there would be no way for oil to get in there. But with the flat spot there's a little cavity created right above the cam gear, and if it flings oil up there it would almost be forced into the hole.

Good luck. For all our sakes.
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post #565 of 5449 Old 02-11-2011, 01:27 PM
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Originally Posted by kgginslc View Post
Very interested to hear how this turns out.

In thinking about that hole you'll put above the lower bushing, it looks to me that the flat spot that you're going to grind in is absolutely necessary. From the picture of cam and OPDA in the engine that is posted on page 1 of this thread it looks like that part of the OPDA is covered by the block, and without the flat spot there would be no way for oil to get in there. But with the flat spot there's a little cavity created right above the cam gear, and if it flings oil up there it would almost be forced into the hole.

Good luck. For all our sakes.

That flat spot cannot be put in any random place either. It needs to be cut into the side of the unit facing the cam gear. If it's facing away from the gear, I don't think the oil will travel up the gap.

Another important thing I need to do would be to seal the 3 oil channels that surround the lower bushing. If they aren't sealed, the oil going into the unit might just drain back down those channels instead of going down the shaft/bushing gap.
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post #566 of 5449 Old 02-11-2011, 01:36 PM
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Wouldn't it be fun to have every 05 & 06 Owner drive thier Wranglers into Jeep Dealers all over the Country on the same day at the same time. Maybe we would make the nightly news

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Loved & Lost due to Faulty OPDA--2005 Jeep Wrangler Unlimited LJ. Rough Country 2.5" Lift w/Stearing Stab. R/C sway bar discos. 31x10.50, Hella Windshield Lights & A Never Ending List of Dreams
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post #567 of 5449 Old 02-11-2011, 01:40 PM
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If I trade off my 05 Unlimited 6spd for an 04.5 Unlimited auto does this opda issue go away? My 2 biggest complaints about my Jeep is the noisy trans & the OPDA's.

Stock till its paid off 2008 Jeep Wrangler Unlimited 4dr. JK
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post #568 of 5449 Old 02-11-2011, 02:44 PM
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Originally Posted by 05LongJeep View Post
Wouldn't it be fun to have every 05 & 06 Owner drive thier Wranglers into Jeep Dealers all over the Country on the same day at the same time. Maybe we would make the nightly news
They would just tell us our OPDAs are fine and charge us $100

Hoping the FogMod 1.0 proves itself over time, also interested to see how other modifications turn out. Although I don't think I'll be doing anything further to my OPDAs, other than greasing and inspecting them every 5 or 10,000 miles.

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post #569 of 5449 Old 02-11-2011, 03:41 PM Thread Starter
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tkki, great info and great job on the pics. I've updated the comparison and dissection section with some of your images. You plan looks a little too complicated for the average Joe, but I can't wait to hear the results.

I don't understand the thought behind grooving the bushing instead of the shaft. Can you expand on that?
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post #570 of 5449 Old 02-11-2011, 03:52 PM
tkki1230
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I just pulled the OPDA replacement unit out of my jeep to check the wear. This unit has the FOGMOD. Here's a pic of the shaft after 6000 miles.




The upper bushing area on the shaft where the grease is looks really good. Just a little discolored, but no wear or scoring. Nice and smooth! The lower bushing was scored about a thousandth. That seemed kind of excessive for just 6000 miles. I'm going to send this to the machine shop to get fixed.

The upper bushing in the unit was perfect. So far so good with the FOGMOD, as far as my unit goes.

The lower bushing wasn't too bad, but there was a little wear, about half a thousandth.
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