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Unread 12-26-2010, 09:58 AM   #1396
jeffjeep1
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Dedicated grease gun

My version has:
1. Pistol grip to allow grease pump with one hand while supporting gun
2. Attached needle point, since I have the flush grease fitting in the OPDA. This allows one hand to hold and pump the gun while the other hand holds the applicator. I dis-assembled a needle adapter to discover the correct 1/8" NPT thread at the base of the tip. Screws right on the flex hose, eliminating one potential leak/flex/come apart point.

Filled with Aeroshell 33MS. A slight odor, but I like it.

img_4427.jpg  
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Unread 12-26-2010, 12:23 PM   #1397
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Quote:
Originally Posted by jeffjeep1 View Post
My version has:
1. Pistol grip to allow grease pump with one hand while supporting gun
2. Attached needle point, since I have the flush grease fitting in the OPDA. This allows one hand to hold and pump the gun while the other hand holds the applicator. I dis-assembled a needle adapter to discover the correct 1/8" NPT thread at the base of the tip. Screws right on the flex hose, eliminating one potential leak/flex/come apart point.
Mine looks just like that. I need a longer and more flexible hose to get in there while it's installed.

You have to have a pistol grip for the flush mount style. The only thing I'm not sure about is generating enough pressure to squeeze the grease into the tiny gap between the bushing and the shaft.
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Unread 12-26-2010, 01:41 PM   #1398
jeffjeep1
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My modded OPDA is installed now (as of 13:00 today). I did grease it on the bench, yesterday. Initially felt resistance, then grease flowed in as one expects. I think it is the small needle opening being sealed by the spring pressure of the ball. One the pressure exceeds the spring, it flows in.

Growing up, I used to have a fitting that threaded onto the grease tube/hose with a rounded ball end that fit into the "bowl" of the flush fittings. Unfortunately that piece is long gone. Thinking about it, the OD of the needle seals better into the fitting with less grease spreading around.
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Unread 12-26-2010, 02:08 PM   #1399
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I had to add an adapter to get the needle to fit into the engine bay to reach the fitting. I also had a spring hose support that I have to slide up. My stock grease gun hose was 12 inch and it just fits.

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Unread 12-27-2010, 12:36 PM   #1400
mukluk
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Well, y'all manged to get me all paranoid so I went and pulled the OPDA from my '05 with 36k and the distributor from my '00 with 133k for reference... I'm thinking I'll be swapping the gear on the '05 but can you tell which gear is which vehicle?
drivegear1.jpg   drivegear2.jpg  
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Unread 12-27-2010, 03:21 PM   #1401
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The upper is the 05...
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Unread 12-27-2010, 03:49 PM   #1402
mukluk
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Quote:
Originally Posted by Knuckelhead View Post
The upper is the 05...
You sir, are correct. Wonder why the newer part wore so unevenly... the area in the pic is the worst wear area, the rest of the gear wear pattern is half the size.
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Unread 12-27-2010, 05:50 PM   #1403
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Just thinking out loud....
Could it be possible to drill straight down the center of the shaft to the center of the upper bushing and drill a cross hole right at the center of the upper bushing? You could then tap the top for a small fitting and just pull the dust cover to grease it from time to time. I'm no machinist but I have seen this type of set up in other applications. I.E.- Possibly a 1/8" hole down the center and a 1/16" cross hole.
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Unread 12-27-2010, 06:40 PM   #1404
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Quote:
Originally Posted by OldenEagle View Post
Just thinking out loud....
Could it be possible to drill straight down the center of the shaft to the center of the upper bushing and drill a cross hole right at the center of the upper bushing? You could then tap the top for a small fitting and just pull the dust cover to grease it from time to time. I'm no machinist but I have seen this type of set up in other applications. I.E.- Possibly a 1/8" hole down the center and a 1/16" cross hole.
What would be the benefit of that compared to going through the bushing? It seems more difficult and could weaken the shaft. It's not too difficult to get to the zerk on the housing. The flush mount zerk is a little more difficult, but not enough to justify trying to drill through the shaft. You could drill through both sides of the bushing if you wanted more grease access.

If we are brainstorming, I was thinking of removing the upper bushing and seal. Cutting the upper bushing in half so that when reinstalled you add the bushing followed by the seal. You could make up the difference in the bushing length with a thicker plastic washer. That could duplicate the 2004 model OPDA and allow oil to contact both bushings.

I don't know how difficult it would be to remove the bushing and seal. FOG may have some suggestions on if it's feasible.
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Unread 12-27-2010, 09:52 PM   #1405
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You must know that cutting the upper bushing clear in two would not be productive?
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Unread 12-28-2010, 08:07 AM   #1406
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Quote:
Originally Posted by OldenEagle View Post
You must know that cutting the upper bushing clear in two would not be productive?
I'm no expert. I suppose the 2005-06 OPDA may need the extra support because of the target wheel. Otherwise why not make it exactly like the old style bushing from the factory? The factory bushing sticks up about 3/4 inch. That doesn't seem like much to me. The internal section of the bushing and seal is an inch or so (I'm going off memory).

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Unread 12-28-2010, 12:12 PM   #1407
joe_jeep
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$29.99 a gallon for 5w40 m1, plus a wix filter. im gonna have about 50$ dollars in one oil change.
at this rate 2 oil changes wil pay for a new opdg. its getting changed right now with m1, but im looking for cheaper alternatives. at the very least i will go to 5k or 6k mile oil changes.

1) is valvoline vr1 any cheaper?

2) what dino oil has the best zddp level?

3) what do the zddp additives cost, and do they work?
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Unread 12-28-2010, 01:02 PM   #1408
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Okay, something I missed here. What is the object of using a flush fitting that needs a needle adapter? What is wrong with an ordinary grease zerk? I've done 2 of these now and the grease zerk seems to work just fine.

One observation on the '06 model I did a couple days ago. This Jeep has about the same mileage as mine, 20K plus or minus, and was built the same month, 8/05. Both are Rubicon LJ's, his has an auto, mine is a 6 speed. Mine had a noticeable less amount of wear on the gear. The shaft looked the same on both. I don't think his gear is shot and we re-used it, but mine had less wear. I use Mobil 1 High Mileage 10-30 and Donaldson 50299 filters for a 7 quart oil system. I change my oil once a year whether it needs it or not. He takes his to Jiffy Lube type places and has no idea what oil is used. Looking at the gear made him a convert.
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Unread 12-28-2010, 02:25 PM   #1409
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Quote:
Originally Posted by Bigbob View Post
Okay, something I missed here. What is the object of using a flush fitting that needs a needle adapter? What is wrong with an ordinary grease zerk? I've done 2 of these now and the grease zerk seems to work just fine.

One observation on the '06 model I did a couple days ago. This Jeep has about the same mileage as mine, 20K plus or minus, and was built the same month, 8/05. Both are Rubicon LJ's, his has an auto, mine is a 6 speed. Mine had a noticeable less amount of wear on the gear. The shaft looked the same on both. I don't think his gear is shot and we re-used it, but mine had less wear. I use Mobil 1 High Mileage 10-30 and Donaldson 50299 filters for a 7 quart oil system. I change my oil once a year whether it needs it or not. He takes his to Jiffy Lube type places and has no idea what oil is used. Looking at the gear made him a convert.
There is no real difference in the zerk choice. When I did my first install I put the grease fitting hole a little high so there was some clearance issues fitting a traditional grease gun. I went to the flush style zerk because of that. There may be a fear that the aluminum is too weak and the long shank zerk may break off. I don't believe that and I've done two for others on the board and both were with long shank traditional zerks.
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Unread 12-28-2010, 03:40 PM   #1410
joe_jeep
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good news! we just took my opdg out, and it looks like new! so it either it aint wearing, or it was just changed right before i bought it. the squeaking noise form the front end was el chepo brake pads.
it had new pads and rotors on when i got it, proabbly cheap stuff though.
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2006 , 4.0 , camshaft , replacement , tj , warranty , wrangler

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